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Kaiser-Jeep Jeep CJ-3B, Service Manual

The Kaiser-Jeep Jeep CJ-3B Service Manual is a comprehensive guide for maintaining and repairing your classic vehicle. This valuable manual is available for free download from manualshive.com, providing step-by-step instructions, detailed diagrams, and essential tips to ensure your CJ-3B continues to run smoothly.

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Summary of Contents for Jeep CJ-3B

Page 1: ...eneral Data A Lubrication B Tune Up C Hurricane F4 Engine D Dauntless V 6 Engine Dl Fuel System E Exhaust System F Exhaust Emission Control System F4 Engine Fl Exhaust Emission Control System V6 225 Engine F 2 Cooling System G Electrical H Clutch I 3 Speed Transmission J 4 Speed Transmission J l Transfer Case K Propeller Shafts L Front Axle M Rear Axle N Steering 0 Brakes P Wheels 0 Frame R Spring...

Page 2: ...our service library for information related to the 6 volt electrical system or the single brake system SM 1002 R5 no longer available should be retained for information related to the CJ 2A CJ 3A or DJ 3A models equipped with the L4 134 engine The above three manuals provide full service coverage since inception of the Jeep Universal and 1 Jeep Dispatcher model vehicles ...

Page 3: ...ion This manual covers all standard production Jeep Universal models currently being produced at the time this manual was approved for publication Significant changes made in each model since it was first produced are included in the manual A description of each model follows General specifications for each model are listed in Par A 8 Detailed specifications covering major vehicle units are listed...

Page 4: ... of identifying numbers A 5 Vehicle Serial Number The vehicle serial number is stamped on a metal plate located on the dash under the hood It is on the left side of the vehicle for models CJ 5 CJ 5A CJ 6 CJ 6A DJ 5 and DJ 6 as shown in Fig A l It is on the right side of the vehicle for model CJ 3B as shown in Fig A 2 Refer to Par A 3 for specific information on codes F I G A l CJ 5 CJ 5A CJ 6 CJ 6...

Page 5: ... Plate is installed on late production Jeep vehicles The paint code on the plate identifies the paint colors The trim code on the plate identifies the color of all trim parts in the interior of the vehicle To identify paint or trim on vehicles manufactured before the Paint and Trim Option Plate was in stalled see your Jeep dealer Jeep Universals have the plate located on the right hand side of the...

Page 6: ...2 49 kg m 81 2 06 m 48K6 1 23 m 67 1 70 m 138 3 51 m 71 1 82 m 8 20 32 cm F 4 4 3 125 7 93 cm 4 375 11 11 cm 134 2 cu in 2 20 ltr 6 7 1 7 1 1 6 3 1 7 4 1 7 8 1 6 9 1 120 to 130 psi 8 4 a 9 2 kg cm2 75 4000 rpm 15 63 114 lb ft 15 8 kg m V 6 6 3 750 9 525 cm 3 400 8 636 cm 225 cu in 3 69 ltr 9 0 1 160 4200 rpm 33 748 235 lb ft 32 49 kg m 101 2 57 m 48 6 1 23 m 67 1 70 m 1583 4 4 02 m 71 1 82 m 8 20 ...

Page 7: ...ions these services should be performed more often than under normal conditions It should also be remem bered that common short trips and stop and go driving are more severe on lubrication points than Starting Circuit B l8 Tie Rod and Drag Link Sockets B 45 Tires B 64 Transmission and Transfer Case Lubricant Level Check B 30 General B 31 Transfer Case B 32 Transmission B 33 Transmission and Transf...

Page 8: ... T Y U S Imperial Metric As required As required As required As required As required As required As required 2 H Pts 2 pts 1 2 ltrs 6 H pts 5 M pts 3 2 ltrs 3Mpti 3 pts 1 5 ltrs 2 M pts 2 pts 1 2 ltrs 2 Yi pts 2 pts 1 2 ltrs As required Several Drops Several Drops One Drop One Drop 2 c c As required 1 H pts 1 pt 0 6 ltrs 4 qt m 314 qt 3 8 ltrs 4 qt 11 3 34 qt 3 8 ltrs L U B R I C A N T T Y P E Cha...

Page 9: ...h 2 000 miles or 60 days Change each 6 000 miles or 60 days As required As required As required As required As required 1 X A pts 114 pts 0 7 ltrs 2 pts 1 pts 0 9 ltrs As required As required 2 to 4 Drops As required Several Drops One Drop One Drop 2 c c As required 1 M pts 1 pt 0 6 ltrs 4 qt 3 H qts 3 8 ltrs 4 qt 3 A qts 3 8 ltrs Chassis Lubricant Chassis Lubricant MIL L 2105 B Wheel Bearing Lubr...

Page 10: ...ch effectively removes any foreign matter sus pended in the oil A flanged section on the rear of the crankshaft acts as an oil slinger and in com bination with the rear main bearing upper and lower oil seal prevents the leakage of oil from the rear end of the cylinder block Leakage of oil from the front end of the cylinder block is controlled by the crankshaft oil slinger and the front oil seal in...

Page 11: ... front camshaft bearing journal to the keyslot in the front of the camshaft Oil flows from the journal into the keyslot over the woodruff key in the space between the key and the camshaft sprocket and fuel pump eccentric The forward end of the fuel pump eccentric in corporates a relief which allows the oil to escape between the fuel pump eccentric and the camshaft distributor gear The oil stream s...

Page 12: ...000 miles X Continuing each 30 000 miles Check after the first 200 miles 320 km J of operation I f wheel or wheels are changed for any reason have wheel nut torque rechecked after an additional two hundred miles of operation Service mileage shown or every 60 days whichever occurs first Maintenance check on emission system must be performed per information in this manual See text for brakes N j Mil...

Page 13: ... 19 200 km For information on servicing the positive crankcase ventilation system on the Hurricane F4 engine and the Dauntless V 6 engine refer to the Tune up Section B l4 Distributor Hurricane F4 Engine The distributor shaft is lubricated through an oiler mounted on the side of the housing Place three or four drops of light engine oil in the oiler each 2 000 miles 3 200 km Also place one drop of ...

Page 14: ...xible Connector 8 Oil Cup 3 H o n Clamp 9 Clamp A Carburetor Vent Tube 10 Hose 5 Body 11 Clamp 6 Screw and Lock Washer 13 Gasket F I G B 6 O I L B A T H A I R C L E A N E R D A U N T L E S S V 6 E N G I N E 1 WinB Nut 2 Cover 3 Rubber Gasket 4 Cork Gasket 5 Oil Cup 6 Breather 7 Clamp 8 Vent Tube 9 Air Pump Hose from cleaner body and remove the oil from the cup scrape all dirt from the inside Clean...

Page 15: ...ransfer case housings Procedure from the appropriate Par below should be fol lowed to check the lubricant level of the various types of transfer cases and transmissions If the transfer case or transmission fluid levels are found to be abnormally low check both units for any possible leaks B 32 Transfer Case The transfer case fill hole is located on the right side of the transfer case housing To ch...

Page 16: ...hings The condition of the spring bushings is indicated by the alignment of the spring pivot and spring shackle bolts Check the alignment of these bolts and check that nuts are tightened securely B 47 Spring Shackles Rubber bushings are provided on the spring shackles These rubber bushings have no lubrication fitting and it is very important that they never be lubricated B 48 Shock Absorbers Visua...

Page 17: ...ked Refer to proce dure in Par B 56 Note When servicing the Flanged Axle Unit Bear ing Assembly refer to Section N Par N 5 for proper lubrication procedures B 58 Propeller Shafts and Universal Joints The propeller shaft slip joints and universals should be lubricated with a hand compressor grease gun so as to not damage the bearing seals The units should be lubricated with a good quality grease Re...

Page 18: ...rrect procedure for replacing the oil filter B 82 Air Cleaner Care of the air cleaner is extremely vital to the life of the engine Pay particular attention to the amount of dust and dirt in the air taken into the engine through the air cleaner When dust is not noticeable in the air service the air cleaner each scheduled maintenance period Whenever the air is noticeably dusty for example when the v...

Page 19: ...s affecting compression and ignition have been satisfactorily corrected Note To make sure hydro carbon and carbon monoxide emissions will be within limits it is very impotrant that the adjustments be followed exactly as listed on the sticker found in each engine compartment S U B J E C T P A R Fuel Pump C 23 Heat Control Valve C 7 Ignition Cables C 19 Ignition Timing C 14 Ignition Wires C l8 Manif...

Page 20: ...Right Front Engine Mount 2 Frame Ground Strap D A U N T L E S S V 6 tors Prepare a strong solution of baking soda and water and brush it around the terminals to remove any corrosion that is present The cell caps must be tight and their vents sealed to prevent cleaning solution entering the cells After cleaning install cable connectors on terminals and coat the ter minals and connectors with heavy ...

Page 21: ...hould be torqued to 25 to 33 lb ft 3 5 a 4 6 kg m C 5 Torque Cylinder Head s and Manifold a Hurricane F4 Engine Torque the cylinder head bolts with a torque wrench to 60 to 70 lb ft 8 3 a 9 7 kg m Follow the sequence shown in Fig C 4 Do not overlook tightening the cylinder head bolt No 5 in the intake manifold directly under the carburetor opening 10102 F I G C 4 H U R R I C A N E F 4 E N G I N E ...

Page 22: ... Hose Breather to Air Cleaner 3 Grommet Valve1 Cover 4 Crankcase Ventilation Valve 5 Hose Valve to Carburetor X urn F I G C 7 P O S I T I V E C R A N K C A S E V E N T I L A T I O N V A L V E L O C A T I O N D A U N T L E S S V 6 E N G I N E 1 Hose on Engines with Fuel Evaporization Emission Control System Only 22 ...

Page 23: ...d on the right cylinder bank rocker arm cover Fig C 7 and is connected by a hose to a fitting at the base of the carburetor at the intake manifold opening The valve varies the air flow through the crankcase to meet changing condi tions at all engine speeds and loads To check the operation of the system remove the valve with the hose attached from the rocker arm cover With the engine running at fas...

Page 24: ...he exhaust valves are ad justed by removing the tappet cover located on the right side of the engine Place the cylinder to be adjusted on top dead center compression stroke and check the clearance between the valve stem and tappet screw with a feeler gauge If the clearance is less or greater than 016 0 406 mm the valve must be adjusted by loosening the tappet screw locknut and turning the screw un...

Page 25: ...es Firmly insert compression gauge in spark plug port Fig C 10 Crank engine through at least four compression strokes to obtain highest possible reading Check compression of each cylinder Repeat com pression check and record highest reading obtained on each cylinder during the two pressure checks Note The recorded compression pressures are to be considered normal if the lowest reading cylinder is ...

Page 26: ...ap after locking the adjustment Apply a thin film of cam lubricant to the cam to lessen fiber block wear Should a condenser tester be available the capacity should check from 21 to 25 microfarads In the absence of a tester check by substituting a new condenser Check point contact spring pressure which should be between 17 and 20 ounces 0 487 a 0 56 kg Check with a spring scale hooked on the breake...

Page 27: ... Eccentric Screw 4 Distributor Cap 8 Adjusting Lock Screw Rotation Firing Order Specifications for the V 6 Prestolite distributor are as follows The condenser capacity must be 25 to 28 mfd contact breaker arm tension 17 to 22 ounces 482 a 624 gr and breaker point gap 016 0 406 mm The cam angle must be set at 29 3 with distributor vacuum line discon nected C 11 Replacement and Adjustment of Prestol...

Page 28: ...ys check ignition timing C 14 Check Ignition Timing a Hurricane F4 Engine If a neon timing light is available use it to check igntion timing following the instructions of the timing light manufacturer In the absence of a timing light remove No 1 spark plug and turn the engine over until No 1 piston is on compression stroke as indicated by air being forced from No 1 spark plug opening Turn the engi...

Page 29: ...ire from the coil Connect the voltmeter positive f lead to the distributor terminal of the ignition coil Ground the negative lead of the voltmeter 12156 F I G C 2 0 I G N I T I O N P R I M A R Y C I R C U I T R E S I S T A N C E C H E C K 1 Distributor 2 Distributor Primary Terminal 3 Coil 4 Ignition Resistor 5 Ignition Switch 6 Ignition Switch Side of Resistor 7 Positive Battery Terminal 8 Batter...

Page 30: ...lation will per mit crossfiring or missing of the engine defective wires should be replaced C l9 Test Ignition Cables To remove cables from spark plugs use Spark Plug Cable Remover Tool W 274 Twist the boot slightly to break the seal and grasping the rubber protector boot lift straight up with a steady even pull Do not grasp the cable and jerk the cable off this will damage the cables Do not use a...

Page 31: ...xture is incorrect Look for the cause in the fuel system d A rhythmic pulsating reading is caused by a condition affecting one or more cylinders but not all and indicates leaky valve gasket blowby re stricted intake port or an electrical miss e An intermittent pulsating reading is caused by an occasional malfunction such as a sticking valve all valves may be erratic in operation if the valve sprin...

Page 32: ...Clamp Bracket 2 Choke Shaft and Lever Assembly 3 Fuel Inlet Elbow 4 Bowl Vent Tube 5 idle Air Adjusting Needle 6 Throttle Lever and Shalt Assembly 7 Idle Speed Adjusting Screw 8 Fast Idle Connector Rod F I G C 2 5 C A R B U R E T O R F 4 E N G I N E L A T E M O D E L 1 Choke Clamp Bracket 2 Throttle Lever and Shaft 3 Choke Shaft and Lever 4 Bowl Vent Tube 5 Fuel Inlet Elbow 6 Dash Pot Bracket 7 Th...

Page 33: ...ion Gauge W 283 The correct tension on a used belt is 70 to 80 pounds 31 7 a 36 2 kg and on a new belt 110 to 120 pounds 49 8 a 54 5 kg When preparing for delivery of new car the belt strand tension should be 80 to 110 pounds 36 2 a 49 8 kg When installing a new belt adjust the strand tension 110 to 120 pounds 49 8 a 54 5 kg Adjust the fan belt tension by loosening the clamp bolt on the alternator...

Page 34: ...ystem Defective Valve Lifter Hydraulic VALVES STICKING Warped Valve Improper Tappet Clearance Carbonized or Scored Valve Stems Insufficient Clearance Valve Stem to Guide Weak or Broken Valve Spring Valve Spring Cocked Contaminated Oil OVERHEATING Inoperative Cooling System Theromstat Inoperative Improper Ignition Timing Improper Valve Timing Excessive Carbon Accumulation Fan Belt too Loose Clogged...

Page 35: ...8 030 0 762 mm 25 to 33 lb ft 3 5 a 4 6 kg m 120 to 130 psi 8 4 a 9 2 kg cm2 018 0 460 mm 016 0 406 mm 9 B T C P R E S T O L I T E IAY 4012 IAY 4401A IAY 4401 IAY 4401B 42 020 0 508 mm 17 to 20 oz 0 482 0 567 gr 1 3 4 2 Counterclockwise 5 B T C 0 T D C Vibration Damper or Timing Cover 600 rpm 1 3 4 2 650 700 rpm 700 750 rpm 12 Volts Negative 1 260 1 225 10 Volts A C 44S or Champion UJ12Y 035 0 889...

Page 36: ......

Page 37: ...tting Crankshaft Main Bearings Using Shim Stock D 46 Floating Oil Intake D 64 Flywheel D 67 Flywheel Housing D 71 S U B J E C T F A R Flywheel Inspection D 68 Flywheel Pilot Bushing D 70 Inspection D 34 Inspection of Valves Springs and Guides D 57 Installing Connecting Rod Bearings D 49 Oil Pan D 66 Oil Pump D 65 Piston Ring Application Chart D 3 7 Pistons Rings and Connecting R o d s D 36 Refacin...

Page 38: ...linder head The cylinder head assembly when installed on the engine consists of the inlet valve guides inlet valves inlet valve springs rocker arm and shaft assemblies spark plugs temperature indicator fitting water outlet fitting and other assembled parts The carburetor and air cleaner assembly bolt to the top of the cylinder head The rocker arm cover is attached to the top of the head to enclose...

Page 39: ...Valve 9 Cylinder Head Gasket 10 Exhaust Valve Guide 11 Exhaust Manifold 12 Exhaust Valve Spring 13 Valve Spring Cover 14 Oil Pump Gear 15 Camshaft 16 Oil Pump 17 Relief Plunger 18 Relief Plunger Spring 19 Relief Spring Retainer 20 Oil Pan 21 Drain Plug 22 Oil Float Support 23 Oil Float 24 Crankshaft 25 Engine Rear Plate 26 Cylinder Block 27 Connecting Rod 28 Oil Filler Tube 29 Piston 30 Cylinder H...

Page 40: ...e Push Rod 22 Exhaust Valve Guide 23 Exhaust Manifold 24 Exhaust Valve Spring 25 Cylinder Block 26 Piston Pin 27 Exhaust Tappet Adjusting Screw 28 Engine Rear Plate 29 Camshaft 30 Flywheel 31 Crankshaft Rear Bearing Seal 32 Crankshaft Rear Bearing 33 Intake Valve Tappet 34 Crankshaft 35 Crankshaft Bearing Dowel 36 Oil Float Support 37 Oil Float 38 Crankshaft Center Bearing 39 Connecting Rod Bearin...

Page 41: ...ignition primary wire at the ignition coil NOTE ON ENGINES E Q U I P P E D WITH E X HAUST EMISSION CONTROL R E M O V E T H E A I R PUMP A I R DISTRIBUTION MANI F O L D AND A N T I B A C K F I R E D I V E R T E R V A L V E S E E SECTION F l FOR P R O C E D U R E m Disconnect the oil pressure and temperature sending unit wires at the units n Disconnect the exhaust pipe at the exhaust manifold by rem...

Page 42: ...C for reference for reinstalling the oil pump without greatly disturbing the ignition timing First remove the distributor cover and note the position of the distributor rotor If the distributor is already removed sight through the distributor hole before removing the oil pump The slot should be near vertical Remove the capscrews and lockwashers attaching the oil pump to the cylinder block Carefull...

Page 43: ...ngine Plate Rear 11 Woodruff Key 12 Camshaft Thrust Plate 13 Spacer 14 Camshaft Gear 15 Washer 16 Crankshaft Shim 002 17 Crankshaft Thrust Washer 18 Crankshaft Gear 19 Spacer 20 Oil Slinger 21 Crankshaft Oil Seal 22 Packing Ring 23 Gear Cover Gasket 24 Gear Cover 25 Pulley 26 Crankshaft Pulley Nut 27 Timing Indicator 28 Engine Support Front Insulator 29 Front Engine Plate 30 Bolt 31 Front Plate Ga...

Page 44: ...ver Remove the bolts nuts and lockwashers that at tach the timing gear cover to the engine Remove the cover timing pointer and cover gasket Dis card the gasket Remove the crankshaft oil seal from the timing gear cover and discard the seal Remove the oil slinger and spacer from the crank shaft D 22 Remove Timing Gears Use puller W 172 for pulling both the crankshaft and the camshaft gears With the ...

Page 45: ...shaft thrust plate attaching screws Remove the camshaft thrust plate and spacer d Pull the camshaft forward out of the cylinder block using care to prevent damage to the cam shaft bearing surfaces D 29 Remove Valve Tappets Remove the intake and exhaust valve tappets from the bottom or crankshaft side of the cylinder block after the camshaft has been removed Tag each tappet or place them in a marke...

Page 46: ...ap Nut 50 Center Main Bearing Cap 51 Front Main Bearing Cap 52 Screw and Lockwasher 53 Screw and Lockwasher 54 Oil Pump 55 Gasket 56 Crankshaft Shim 57 Crankshaft Thrust Washer 58 Gasket 59 Stud 60 Exhaust Valve Spring Cover 61 Gasket 62 Valve Spring Retainer Lower Lock 63 Roto Cap 64 Exhaust Valve Spring 65 Camshaft Front Bushing 66 Timing Gear Oil Jet 67 Camshaft 68 Camshaft Thrust Plate 69 Spac...

Page 47: ...g tool Operate the hone or deglazer to obtain diamond cross hatched pattern previously mentioned d Regardless of type of correction on cylinder walls wash out bores thoroughly afterwards and apply a light coat of engine oil If cylinders have been rebored or honed heavily measure cylinder diameters again to assure proper selection of piston size D 36 Pistons Rings and Connecting Rods Pistons are ea...

Page 48: ...ngine is not recommended as experience has shown that should a pin be worn sufficiently to require replace ment the piston should also be replaced Clamp the connecting rod in a vise using jaw shields of soft metal or two pieces of hardwood one on each side of the rod and positioned approximately 3 76 mm from the piston pin end Start 10278 j F I G D 8 C H E C K I N G C O N N E C T I N G R O D A L I...

Page 49: ...ted piston as a plunger to push ring in squarely End gap must be as shown in Par D 37 for all rings If less file ends to obtain minimum gap With cylinders bored to an exact ring oversize of 020 030 or 040 0 508 0 762 1 016 mm the proper end clearance as given in Par D 37 will result If end gaps are not within the limits given in Par D 3 7 rings are of the wrong size or were incorrectly filed for f...

Page 50: ...rilled oil passages in the crankshaft journals with a small rifle brush making sure to get rid of all sludge or gum deposits Blow out the passages with compressed air after cleaning Clean the crankshaft thoroughly with a suitable cleaning solvent Inspect the crankshaft for cracks alignment and condition of the crankpins and the main bearing journals Use magnafuix equipment if available to check fo...

Page 51: ...t the bearing lock fits properly in the notch in the block Install the crankshaft if replacing bearings with the engine out of the vehicle The desired running fit dif ference between the diameter of the crankshaft journal and the inside diameter of the fitted bear ing for a main bearing is 0003 to 0029 0 0076 a 0 0736 mm With a dimension in excess of this standard running fit a satisfactory bearin...

Page 52: ...terchanged for if they are reversed the oil spray hole will be on the wrong side No 1 and 3 or No 2 and 4 can be interchanged Connecting rod bearings should be replaced as a complete set Each bearing consists of two halves Connecting rod bearing sets are available in stand ard size and the following undersize 001 0 025 mm 012 0 305 mm 002 0 051 mm 020 0 508 mm 010 0 254 mm 030 0 762 mm The 001 and...

Page 53: ...eccentric forged onto the camshaft Clean the camshaft thoroughly in cleaning solvent Inspect all camshaft bearing surfaces to determine if they are scored or rough The cam faces must be perfectly smooth throughout their contact face and must not be scored or worn D 52 Camshaft F r o n t Bearing Replacement Use a suitable driver to remove the camshaft front bearing from the cylinder block To instal...

Page 54: ...alve spring retainer locks make up the remainder of the valve operating parts An intake valve spring retainer oil seal which encircles the upper end of the intake valve between the valve locks and the upper end of the valve spring re tainer controls the passage of oil along the valve stem and guide Note When engine trouble indicates defective valves as a possible source of trouble also check all v...

Page 55: ...ive oil consump tion fouled spark plugs and poor low speed per formance To check the clearance of the valve stem to the valve guide take a new valve and place in each valve guide Check the clearance with a suitably mounted dial indicator or feel the clearance by moving the valve stem back and forth If this check shows excessive clearance it will be necessary to replace the valve guide D 58 Refacin...

Page 56: ... the valve face Check by applying an extremely thin coat of pencil lead or bearing fitting blue to the seat Then install and rotate the valve with light pressure Blue or pencil marks will transfer to the face of the valve If the blue is near the top edge of the valve face lower the valve seat by using the valve seat relief counter bore If the blue is transferred to the bottom edge of the valve fac...

Page 57: ...ating oil pressure can usually be traced to an air leak between the oil float support and the crankcase Be sure the float support flange is flat Clean both the flange and the crankcase surfaces thoroughly before installing a new gasket Be sure the retaining screws are tight D 65 O i l P u m p The oil pump is located externally on the left side of the engine In operation oil is drawn from the crank...

Page 58: ...and Rotors 15 Cover Gasket 16 Cover Oil Pump 17 Oil Pan Gasket 18 Oil Pan 19 Drain Plug Gasket 20 Oil Pan Drain Plug 21 Lockwasher 22 Fan Pulley Shield 23 Spacer 24 Stud Oil Filter Bracket 2 5 Lockwasher 2 6 Retainer 2 7 Gasket 28 Shim 29 Spring 3 0 Plunger 3 1 Gasket 3 2 Oil Float Support 33 Oil Float Assy 3 4 Cotter Pin 35 Elbow Fitting 36 Oil Filter Tube Inlet 3 7 Oil Filter Tube Outlet 38 Jam ...

Page 59: ...ssure at higher speeds but not at idle speed Safe minimum pres sure is 6 psi 0 4 kg cm2 at idle at which point the oil pressure light goes out and 20 psi 1 4 kg cm2 at 2000 rpm 32 mph 51 kph D 66 Oil Pan Examine the oil pan carefully for evidence of cor rosion dents or other damage Special attention should be given to the mounting flange to be sure of proper alignment and a tight seal at the cylin...

Page 60: ...ywheel For procedure on replacing the bushing refer to Par 1 8 D 71 Flywheel Housing The flywheel housing which encloses the flywheel and clutch is bolted to the engine rear plate and cylinder block The rear of the housing provides the front support for the transmission Examine the housing for cracks and distortion of the machined surfaces The front face must seat evenly against the engine rear en...

Page 61: ...Par D l5 and Fig D 32 for removal of the valve and elbow 13342 F I G D 3 2 C R A N K C A S E V E N T I L A T I O N V A L V E 1 Ventilation Valve 2 90 Elbow 3 Cylinder Head D 74 Rocker A r m s The rocker arms and their related parts are mounted on the top of the cylinder head and en closed by the rocker arm cover The rocker arm shaft supported in four rocker arm shaft brackets carries the rocker ar...

Page 62: ...he cylinder block in an engine repair stand If an engine stand is not available perform the fol lowing reassembly operation in a manner designed to protect personnel against an accident and the engine and its parts against damage Note During engine reassembly use Perfect Seal Aerosol Spray Sealer Part No 994757 on all engine gaskets to ensure against vacuum oil gasoline and water leaks Apply to he...

Page 63: ...nkshaft End Play End play of the crankshaft is set by the running clearance between the crankshaft thrust washer and the front face of the front main bearing The standard end play is 004 to 006 0 102 a 0 152 mm which is controlled by 002 0 051 mm shims placed between the thrust washer and the shoulder on the crankshaft Check the end play with a dial indicator as shown in Fig D 34 If clear ance is ...

Page 64: ...ing cap in the crankcase place a small amount of plastic type gasket cement on both sides and face of the cap to prevent oil leakage Insert the rubber packings shown in Fig D 3 7 into the holes between the bearing cap and the case Do not trim these packings The packings are of a predetermined length that will cause them to protrude approxi mately 34 6 mm from the case When the oil pan is installed...

Page 65: ...ock are clean and smooth Place the flywheel housing in position and attach to the cylinder block and engine rear plate The long bolts through the lugs on the engine crankcase and those below are installed with the nuts on the flywheel housing side Install the other bolts from the rear except the screw used to attach the top side of the starting motor Tighten securely D 89 Install Clutch To install...

Page 66: ...of the cylinder block start the oil pump drive shaft into the opening in the left side of the cylinder block with the mounting holes in the body of the pump in alignment with the holes in the cylinder block Insert a long blade screw driver into the distributor shaft opening in the opposite side of the block and engage the slot in the oil pump shaft Turn the shaft so that the slot is positioned at ...

Page 67: ...sequence shown in Fig D 41 Do not overlook installing the cylinder head bolt in the intake manifold directly under the car buretor opening D 99 Install Rocker Arm Assembly a Insert ball ends of the intake valve push rods through the cylinder head and cylinder block and seat them in the cupped head of the intake valve tappets b Install the rocker arm assembly on the four rocker arm mounting studs A...

Page 68: ...two x 4 inch guide bolts or dowels should be used to properly guide and align the engine to the flywheel housing See Fig D 42 b Slightly tilt the engine downward and at the same time slide the engine rearward while lining up the transmission main gear shaft with the clutch throw out bearing and disc spline Note The engine crankshaft may have to be turned slightly to align the transmission main gea...

Page 69: ... gauge To adjust hold the tappet with one wrench and turn the adjusting screw with the other Check and adjust each of the tappets in proper sequence Adjust each intake valve by adjusting the rocker arm screw at the push rod to obtain 018 0 457 mm clearance between the rocker arm and the valve stem with tappet on the heel of the cam D 109 Check Valve Timing To check the valve timing carefully set t...

Page 70: ...ng Valves or too Loose in Guides Improper Timing Excessive Carbon Around Valve Head and Seat Overheating Valve Spring Weak or Broken Burned Valves and Seats Continued Valve Tappet Sticking Valve Tappet Clearance Incorrect Clogged Exhaust System Valves Sticking Warped Valve Improper Tappet Clearance Carbonized or Scored Valve Stems Insufficient Clearance Valve Stem to Guide Weak or Broken Valve Spr...

Page 71: ...1 No 2 and 3 Width No 1 and 2 No 3 Gap Std to 009 Cyl Bore Thickness No 1 and No 2 R i n g s No 3 Ring Side Clearance in Groove No 1 Ring No 2 Ring No 3 Ring P I S T O N P I N S Material Length Diameter Type Clearance in Piston selective fit Aluminum Alloy Gam Ground T slot Tin Plated 3 1225 to 3 1245 13 5 oz Selective Feeler F i t 1593 to 1655 1693 to 1755 0955 to 0965 095 to 096 1875 to 1885 760...

Page 72: ... Forged Steel 32 oz 9 187 Removable Steel backed Babbitt 1 089 to 1 099 001 to 0019 001 002 010 012 020 030 004 to 010 From Above 8115 to 8125 2 0432 to 2 0440 S A E 1040 Forged Steel Front Bearing 004 to 006 Removable Steel backed Babbitt 0003 to 0029 001 002 010 012 020 030 2 333 to 2 334 1 64 1 72 1 66 001 Right 125 1 9375 to 1 9383 005 Steel backed Babbitt Front only 4 001 to 0025 2 1860 to 2 ...

Page 73: ...s Camshaft Bearings Tappets Timing Gears Cylinder Walls Oil Pump Type Drive Minimum Safe Oil Pressure At Idle At 2000 rpm 35 mph Relief Valve Opens Normal Oil Pressure Oil Pressure Sending Unit Oil Intake Oil Filter System E N G L I S H 9 B T C 50 A B C 239 47 B B C 12 A T C 239 21 SAE 5150 4 781 2 46 3733 to 3738 0007 to 0022 260 Uniloy 21 12 5 909 1 47 46 Eatonite E M S 58 371 to 372 0025 to 004...

Page 74: ......

Page 75: ...ing and Inspection Dl 52 Flywheel Housing Cleaning and Inspection Dl 54 Hydraulic Valve Lifter Leakdown Test Dl 57 Main Bearing Fitting or Shim Stock Dl 42 Dl 43 Oil Pan Cleaning and Inspection Dl 51 PAR and Inspection Dl 68 Oil Pump Intake and Screen Cleaning Dl 50 Piston and Rod Assembly Dl 48 Piston and Rod Cleaning and Inspection D1 45 Piston and Rod Disassembly Dl 44 Piston Fitting Dl 46 Pist...

Page 76: ...4 front to rear The thrust bearing is flanged to maintain crankshaft position and to compensate against crankshaft end thrust The No 2 bearing is the thrust bearing The crankshaft is counterbalanced by weights which are cast integral with the crank cheeks The weights are shaped to a contour which gives mini mum clearance with cylinder barrels and piston skirts to conserve space Connecting rods hav...

Page 77: ...cam follower At the beginning of valve operation the valve lifter body rests on the camshaft base circle Plunger spring tension prevents lash clearances in the valve linkage As the camshaft forces the valve lifter body up ward both oil in the lower chamber and check ball spring tension firmly seat the check ball against the plunger to prevent appreciable loss of oil from the lower chamber Oil pres...

Page 78: ...ter Passages 18 Exhaust Manifold 19 Piston 20 Camshaft 21 Crankshaft 22 Main Bearing Cap 23 Oil Pan 24 Crankcase 25 Connecting Rod The engine is pressure lubricated The oil pump is located on the timing chain cover and discharges oil through an oil filter into main oil galleries in the crankcase to deliver oil to all crankshaft and camshaft bearings Piston pins are lubricated by splash The timing ...

Page 79: ... radiator support bars j Remove radiator from the vehicle k Disconnect engine wiring harnesses from con nectors located on engine firewall I On engines equipped with exhaust emission con trol remove the air pump air distribution manifold and anti backfire gulp valve See Section F2 for procedure m Disconnect battery cable and wiring from en gine starter assembly n Remove engine starter assembly fro...

Page 80: ...t and exhaust mani fold from each cylinder head Dl 9 Remove Distributor Disconnect vacuum hose and wiring harness from distributor Disconnect spark plug cables from spark plugs Remove sparks plugs from engine Pull spark plug cable retainers from brackets on rocker arm covers Remove mounting screw retainer bracket and distributor from timing chain cover If timing chain and sprockets are not to be r...

Page 81: ...per to crankshaft Tap vibration damper with a soft headed hammer to remove it from crankshaft Dl 19 Remove Oil Pump Remove five screws oil pump cover and gasket from right side of timing chain cover Remove two oil pump gears D1 20 Remove Timing Chain Cover Refer to Fig Dl 6 Remove two bolts which attach oil pan to timing chain cover Remove five mounting bolts timing chain cover and gasket from cyl...

Page 82: ...ton and Pin Assy 4 Ring Set 5 Connecting Rod Bolt and Nut 6 Connecting Rod Bearing 7 Damper Spring 8 Damper Bolt 9 Timing Chain Damper Right 10 Cylinder Block 11 Camshaft 12 Woodruff Key 13 Camshaft Bearing No 1 Front 14 Camshaft Bearing No 2 15 Camshaft Bearing No 3 16 Camshaft Bearing No 4 Rear 31 17 Camshaft Plug Rear 32 18 Flywheel 33 19 Ring Gear 34 20 Crankshaft Bearing Set 35 21 Main Bearin...

Page 83: ...lts and flywheel housing from cylinder block b Mark clutch cover and flywheel to assure that clutch will be installed in identical position when engine is assembled c Remove six attaching screws and clutch assem bly from flywheel D1 28 Remove Flywheel Refer to Fig Dl 6 Remove six attaching bolts and flywheel from engine crankshaft Dl 29 Remove Oil Pan Refer to Fig Dl 5 To gain access to oil pan mo...

Page 84: ...ngine cylinder block Do not remove upper main bearing halves from block or lower main bearing halves from caps at this time Mount main bearing caps in their original positions Dl 33 ENGINE CLEANING INSPECTION AND REPAIR The cleaning inspection and repair procedures detailed herein are recommended to be followed when a complete engine overhaul is to be made with the engine out of the vehicle These ...

Page 85: ... possible oversize service pistons should be used and the cylinder bores should be honed to size for proper clearance Before honing or reboring cylinders measure all new pistons with a micrometer on an axis perpen dicular to the piston pin Select the smallest piston for the first fitting The slight variation usually found between pistons in a set may provide for correction in case the first piston...

Page 86: ...block The upper cylinder block half of the bearing is grooved to supply oil to the con necting rod bearings while the lower bearing cap half of the bearing is not grooved The two bearing halves must not be interchanged All crankshaft bearings except the thrust bearing and the rear main bearing are identical The thrust bearing No 2 is longer and it is flanged to take crank shaft end thrust When the...

Page 87: ...learance is correct the strip should cause a light to heavy drag or resistance to rotation If there is little or no drag clearance is too great if the crankshaft cannot be turned clearance is insufficient In either case a different main bear ing must be selected to obtain proper clearance d Repeat steps a b and c as necessary to select proper main bearing size After a bearing has been selected rem...

Page 88: ...alls should be honed with the finest grade of stone to remove any glaze New compression rings must be checked for clear ance in piston grooves and for gap in cylinder bores however the flexible oil rings are not checked for gap The cylinder bores and piston grooves must be clean dry and free of carbon and burrs With rings installed on piston check clearance in grooves by inserting feeler gauge bet...

Page 89: ... compression ring is used the chrome ring must be installed in the top groove Note All compression rings are marked with a dimple a letter T a letter O or word TOP to identify the side of the ring which must face toward the top of the piston If a single chrome plated compression ring is used the chrome ring must be installed in the top groove Dl 49 Connecting Rod Bearing Inspection and Fitting a I...

Page 90: ...Cleaning and Inspection Clean both camshaft and camshaft bearing surfaces with a suitable cleaning solvent dry with com pressed air Note The steel backed babbitt lined camshaft bearings are pressed into the crankcase From front to rear each bearing is 030 0 76 mm smaller in diameter than the preceding bearing From front to rear each camshaft journal is correspondingly smaller in diameter The camsh...

Page 91: ...or score marks Small score marks with rough satiny finish will cause the plunger to seize when 12751 F I G D 1 2 1 H Y D R A U L I C V A L V E L I F T E R W E A R P A T T E R N S A Incorrect Wear Patterns B Normal Wear Patterns 1 Galled and Pitted 3 Wear 020 Maximum 2 Soft 4 Rotating 5 Non Rotating hot but operate normally when cool Using a magni fying glass inspect the check ball seat for defects...

Page 92: ...ocker arm from each end of the rocker arm shaft b Withdraw two bolts from outer shaft supports and rocker arm shaft Remove outer supports two rocker arms two spacer springs and two remaining rocker arms from shaft Withdraw bolt from center support and remove support from shaft Dl 59 Rocker Arm Cleaning and Inspection a With a wire brush and suitable cleaning solvent clean any sludge or dirt from h...

Page 93: ...ly bolt through each support and shaft to hold supports in position c Install remaining rocker arms of front and rear pairs each with notched face touching shaft sup port Install a spring retaining ring and flat washer at each end of shaft secure each of these with a new cotter pin D1 61 Valve Removal a Place cylinder head on clean smooth surface b Remove each valve assembly from cylinder head as ...

Page 94: ... and reseating should leave the refinished surfaces smooth and true so that a minimum of lapping will be required Ex cessive lapping will groove the valve face and pre vent good valve seating e Test valve seats for concentricity with guides and for proper valve seating Coat a small segment of the valve face lightly with Prussian blue pig ment Insert the valve stem into its guide and turn the valve...

Page 95: ... Gasket 3 Spring 4 Valve 5 Oil Pump Cover c Wash valve parts thoroughly Inspect the relief valve plunger for wear or scoring Check the spring to see that it is not worn or collapsed Replace any relief valve spring that is questionable Thoroughly clean the screen staked in the cover d Insert the relief valve plunger into its bore in the cover The plunger should have no more clear ance than an easy ...

Page 96: ...upper parting line between the cap and cylinder block Dl 73 Main Bearing and Crankshaft Installation Refer to Fig Dl 6 This procedure assumes that crankshaft main bear ings have been inspected and proven satisfactory or that new crankshaft main bearings of appropriate size have been selected If necessary check or select main bearings as described in Par Dl 41 and Pars Dl 42 and Dl 43 a Install fou...

Page 97: ...her or with the oil ring rails e Lubricate the piston and rings Compress the rings with a suitable piston ring compressor install the piston and connecting rod assembly from top of cylinder bore Refer to Fig Dl 33 f Install bearing cap with lower bearing half on connecting rod Torque bolt nuts to 30 to 40 lb ft 4 1 a 5 5 kg m g Install all other piston and connecting rod as semblies in same manner...

Page 98: ...Pan Gasket 4 Oil Pan 5 Drain Plug Gasket 6 Drain Plug 7 Oil Pump Screen 8 Oil Suction Housing Pipe and Flange 9 Oil Suction Pipe Gasket 10 Oil Pump Idler Gear 11 Valve By Pass and Cover Assy 12 Oil Pressure Valve 13 Spring 14 Gasket 15 Oil Pressure Valve Cap 16 Oil Filter 17 Oil Pump Cover Gasket 18 Oil Pump Shaft and Gear 98 ...

Page 99: ...tion flywheel housing to engine cylinder block Secure housing to block with six mounting bolts Torque bolts 30 to 40 lb ft 4 1 a 5 5 kg m D1 80 Install Camshaft Insert camshaft into camshaft bearings of engine cylinder block carefully to avoid damage to bear ing surfaces Make certain camshaft journals are properly seated in bearings 12695 F I G D1 36 CAMSHAFT A N D V A L V E L I N K A G E 1 Rocker...

Page 100: ... is downward Remove key and sprocket from camshaft c Assemble timing chain and sprockets Install keys sprocket and chain assembly on the camshaft and crankshaft so that index marks of both sprockets are aligned as shown in Fig Dl 39 Note It will be necessary to hold spring loaded timing chain damper out of the way while installing timing chain and sprocket assembly d Install front oil slinger on c...

Page 101: ...prime itself when engine is started b The gasket surfaces of the cylinder block and timing chain cover must be smooth and clean In stall a new timing chain cover gasket and position it correctly on the cylinder block Note Two different timing chain cover gaskets have been installed in production on V 6 engines At any time the timing chain cover gasket is replaced make sure the correct gasket is in...

Page 102: ...all Water Pump Be certain that mating surfaces of the water pump and timing chain cover are clean Install a new gasket on the pump flange Secure the pump and alternator adjustment bracket to the cover with nine attaching bolts Torque bolts 6 to 8 lb ft 0 83 a 1 10 kg m Refer to Fig Dl 41 D1 9S Install Cooling Fan Secure the cooling fan fan hub and fan drive pulley to the water pump shaft flange wi...

Page 103: ...heads Thread two cap bolts through manifold into each cylinder head as guide bolts Lift the manifold slightly and insert each of two gaskets into position between manifold and corresponding cylinder head Be certain that the gasket is installed with its three apertures F I G D l 4 4 I N T A K E M A N I F O L D G A S K E T I N S T A L L A T I O N 1 Gasket 2 Guides Bolts aligned with ports of the hea...

Page 104: ...ors located on engine firewall Note On engines equipped with exhaust emission control replace the air pump air distributor mani fold and anti backfire gulp valve See Section F2 m Replace radiator and secure with bolts n Replace and tighten right and left radiator sup port rods 0 Connect upper and lower radiator hoses to the engine p Connect alternator wiring harness from connec tor at regulator q ...

Page 105: ...Burned Valves and Seats Valves Stick or Are Too Loose in Guides Valve Timing Incorrect Valve Head and Seat Have Excessive Carbon Engine Overheats Valve Spring Weak or Broken Valve Lifter Seized or Collapsed Exhaust System Clogged Valves Sticking Valve Stem Warped Valve Stem Carbonized or Scored Valve Stem Clearance Insufficient in Guide Valve Spring Weak or Broken Valve Spring Distorted Oil Contam...

Page 106: ...0127 a 0 0279 mm 0 0127 a 0 0279 mm 4 775 a 5 067 mm 4 839 a 5 029 mm 0 076 mm 0 127 mm P I S T O N R I N G S Function No 1 and No 2 Ring No 3 Ring Location Material No 1 No 2 No 3 Oil Ring Type Oil Ring Expander Width No 1 No 2 No 3 Gap No 1 and No 2 No 3 Side Clearance in Groove No 1 No 2 No 3 Compression Oil Control Above Piston Pin Iron Chrome Plated Iron Pre lubricated Steel Dual Rail With Sp...

Page 107: ...prings Pressure at Length Valve Closed English Pearlitic Malleable Iron From Top of Cylinder Bore Removable Steel Backed Aluminum 737 0020 to 0023 006 to 014 Metric 18 72 mm 0 0508 a 0 0584 mm 0 153 a 0 356 mm Pearlitic Malleable Iron Second Main Bearing 004 to 008 Removable Moraine 100 864 1 057 0005 to 0021 2 4995 2 0000 015 0 102 a 0 203 mm 21 95 mm 2 685 cm 0 0127 a 0 0533 mm 6 349 cm 5 080 cm...

Page 108: ...Chain Cylinder Walls Oil Pump Type Drive Normal Oil Pressure Oil Pressure Sending Unit Oil Intake Oil Filter System Filter Type Crankcase Capacity Without Filter With Filter English Pressure Pressure Splash Pressure Pressure Splash and Nozzle Splash and Nozzle Gear Camshaft Gear 33 psi at 2400 rpm Electrical Screened Tube Full Flow Type Throwaway Element and Can 4 qt 5 qt Metric 2 32 kg cm2 at 240...

Page 109: ... CAUTION Whenever a vehicle is to be stored for an extended period the fuel system should be com pletely drained the engine started and allowed to run until the carburetor is emptied This will avoid oxidization of the fuel resulting in the formation of S U B J E C T P A R Pot Adjustment E 44 nal Carburetor Adjustments E 40 Idle Adjustment E 43 System E 26 Bowl Body Assembly E 38 Fuel Bowl Body Dis...

Page 110: ...ternal carburetor venting The same basic system is used on all Jeep vehicles as shown in Fig E 3 This system involves means of trapping the fuel vapors through the use of a charcoal canister which absorbs the vapor and stores it until it can be re moved to be burned in the engine This removal is performed by drawing these vapors through the purge line into the crankcase ventilation system which in...

Page 111: ... canister there is the demand valve which has connections one vents the vapor to the canister while the other connection joins the canister to the purge system These tubes enter the canister on opposite sides of a baffle which permits uniform vapor distribution throughout the canister The bottom of the canister is fitted with a filter element that allows fuel tank venting to atmosphere after vapor...

Page 112: ...k The vapor lines which lead from the fuel tank are located at the front and rear so that during any inclination of the vehicle at least one line will be open to vent at all times E 6 V a p o r Separator or Expansion T a n k The vapor separator is chambered so that the rear fuel tank vent lines lead into a separate chamber with a fuel shutofl valve This prevents solid fuel from flowing from the fu...

Page 113: ... rubber material Bulk hoses are available for parts service Ordinary rubber hose should not be used to service vapor lines as they are subject to deterioration and may clog the system Liquid vapor separators or expansion tanks and canisters are serviced as complete units only Canister air filters however are serviced separately E 10 C A R B U R E T O R HURRICANE F4 ENGINE A single barrel manual ch...

Page 114: ...ove the bowl cover gasket Allow the weight of the float to rest on the needle and spring Be sure there is no compression of the spring other than the weight of the float Adjust the level by bending the float arm lip that contacts the needle not the arm to provide specified clearance be tween the float and cover The specified clearance of the float is L 74 F 6 74 mm on current models including Exha...

Page 115: ... fuel required As the rod 13346 F I G E 1 0 H I G H S P E E D S Y S T E M 1 Nozzle 7 Pump Diaphragm Spring 2 Metering Rod 8 Diaphragm Assembly 3 Pump Lifter Link 9 Chamber 4 Metering Rod Arm Assembly 10 Metering Rod Jet 5 Diaphragm Shaft 11 Carburetor Casting 6 Upper Pump Spring 12 Carburetor Bore is automatically raised and lowered in the jet the opening in the jet is varied in size to supply fue...

Page 116: ...l on the fast idle rod should con tact the boss on the body casting Adjust by bend ing the fast idle link at offset as shown by No 2 E 19 Accelerating Pump System The accelerating pump system shown in Fig E 12 provides a measured amount of fuel for rapid acceleration and smooth engine operation when the throttle is opened at lower speeds In operation vacuum is applied to the underside of diaphragm...

Page 117: ...e strainer housing using tip of knife blade h With the air horn in an upside down position remove pin and float Invert the air horn and catch needle pin and needle pin spring i Remove metering rod jet Remove low speed jet F I G E 1 3 C A R B U R E T O R 1 Choke Shaft and Lever 2 Screw 3 Choke Lever Spring 4 Screw and Washer 5 Choke Valve Screw 6 Choke Valve 7 Screw and Washer 8 Air Horn 9 Needle S...

Page 118: ... pin spring Connect metering rod spring o Check and if necessary correct meter ing rod adjustment Follow procedure of Par E 16 p Install needle seat and gasket assembly needle float and float pin The stop shoulder on the float pin must be on the side away from the bore of the carburetor q Set float level to specifications Follow pro cedure of Par E 12 r Install air horn gasket and air horn assembl...

Page 119: ...tor is identified by a number and the correct carburetor must be used when replacement is necessary The carburetor fuel bowl is located forward of the main bores The carburetor is compact in design in that all of the fuel metering is centrally located See Fig E 16 This carburetor uses a calibrated cluster design with main well tubes idle tubes mixture passages air bleeds and pump jets in one remov...

Page 120: ...Valve 2 Idle Air Bleed 7 Idle Needle Hole 3 Idle Restriction 8 Adjustment Needles 4 Lower Idle Restriction 9 Main Metering Jets 5 Off Idle Discharge Port 10 Idle Tube A Throttle Valve in Off Idle Position In idle speed position each throttle valve is slightly open This allows a small amount of air to pass between the carburetor bore wall and the throttle valve Since there is not enough air flow fo...

Page 121: ...s carburetor has a two stage power valve I n the first stage fuel is metered by the valve itself This stage occurs under light load During heavy load the valve is fully opened to the second stage in this position the power valve supplies fuel to be metered by power restrictions in the fuel chan nel to the fuel bowl The power piston cavity is connected to the main air flow passage by a vacuum relie...

Page 122: ...t and allow spring to snap re peatedly to remove power piston from air horn body This will force power piston retaining washer from air horn body d Remove retainer from end of accelerator pump plunger shaft Remove pump assembly from pump inner arm Loosen set screw on inner arm and re move outer lever and shaft from plunger Remove gasket from air horn body or fuel bowl body and discard e Remove two...

Page 123: ...mall aluminum inlet check ball in ac celerator pump inlet at bottom of pump well In sert pump return spring into well and center by pressing spring downward with finger e Install pump inlet screen in bottom of fuel bowl E 39 A i r Horn Body Assembly a Install choke lever and collar on choke shaft Prong on choke lever must face away from air horn body and be on top of choke trip lever b Install cho...

Page 124: ...e throttle valves in bore Place pump gauge across top of carburetor air horn ring as shown with 15 29 369 mm leg of gauge pointing downwards towards top of pump rod Lower edge of gauge leg should just touch the top of the pump rod Bend the pump rod as required to obtain the proper setting See Fig E 26 13354 F I G E 2 5 C H O K E L I N K A G E I N S T A L L E D V I E W 1 Choke Lever 2 Trip Lever 3 ...

Page 125: ... E N T F 4 E N G I N E 1 Throttle Lever 3 Dash Pot 2 Plunger 4 Lock Nut springs gaskets and a glass sediment bowl complete with strainer The metal pump body provides a work ing housing for the diaphragm lever valves and springs The fuel pump is mounted on the left side of the engine and is actuated by an eccentric on the camshaft An air dome is cast into the metal cover to relieve the carburetor n...

Page 126: ...nd filtering screen which is attached to the top of the pump by a wire clamp and thumb nut The screen and sedi ment bowl should be cleaned at least twice yearly to prevent trouble due to a blocked screen or water freezing The bowl should be washed and wiped dry and the screen dried and then cleaned with a stiff brush When reassembling the bowl make cer tain that the cork gasket is not broken rever...

Page 127: ... blade If installing new valves be sure the inlet and outlet valves are correctly positioned and stake them lightly with a small punch Assemble the vacuum pump in the reverse order of disassembly drawing the cover attaching screws up evenly and tightly E 49 Fuel P u m p T e s t i n g Four tests are presented in following paragraphs to test for proper operation of the fuel pump In addi tion check t...

Page 128: ... diaphragm Note Do not remove valves from housing as they are serviced with the housing Note The oil seal at top of spring in diaphragm assembly seals the spring side of the fuel dia phragm from the crankcase Any deposit in excess of a few drops of oil on the diaphragm indicates leakage past the oil seal Be sure the seat for the seal in the pump body is clean and smooth E 57 Fuel P u m p C l e a n...

Page 129: ...agm spring This provides a steady sup ply of fuel to the carburetor at a fairly constant pressure E 61 Fuel Pump Removal To remove the fuel pump from the engine dis connect the inlet and outlet fuel lines Remove the two fuel pump body attaching nuts lock washers and washers and pull the fuel pump and gasket free of the engine E 62 Fuel Pump Disassembly Note The fuel pump is serviced with a repair ...

Page 130: ...oil Note Forked end of lever goes around diaphragm shaft Be sure loose bumper washer on diaphragm shaft is on top of lever and between lever and fixed washer on shaft e Install lever and pin To install pin use a drift and tap pin into the hole in the body until it hits the stop on the bottom of the hole move the lever while tapping to align hole in lever with the pin then install plug Install leve...

Page 131: ...A G E The accelerator linkage is properly adjusted when the vehicle leaves the factory However in time components parts will become worn and require re adjustment to maintain a smooth even control of engine speed On Models equipped with F4 engines the adjustment is made at the adjusting block Fig E 34 Loosen the lock nuts and adjust the length of the accelerator rod so that when the car buretor th...

Page 132: ...in the tank of all fuel Remove the driver s seat then remove the tank hold down straps Disconnect fuel line s and sending unit 5 Accelerator Mounting Bracket 6 Accelerator Boot 7 Accelerator Rod Lower 8 Accelerator Treadle wire from the tank Remove the filler neck rubber grommet and remove the tank assembly from the vehicle When removing the fuel tank on late model vehicles first drain the tank of...

Page 133: ... Fuel Evaporative Emis sion System are equipped with a non vent sealed gas cap The sealed cap is designed to allow no vapors to discharge to the atmosphere No other type of cap is to be used on vehicles having this type system E 76 Fuel Gauge Float Unit The fuel tank gauge float unit is mounted in the top of the fuel tank and consists of a housing enclosing a rheostat that is actuated by the float...

Page 134: ... clean Engine Hesitates on Acceleration Accelerator pump does not function perfectly Replace piston and rod or adjust Carburetor float level Adjust Spark plugs Replace or clean and adjust Low compression Check valves Distributor points dirty or pitted Replace Weak condenser or coil Replace Carburetor jets restricted Remove and clean Excessive engine heat See Engine section Engine Stalls Won t Idle...

Page 135: ... cm 1M 3 18 cm 035 0 889 mm 089 dia 2 261 mm 184 x 030 4 70 a 0 765 mm 028 0 713 mm 024 0 609 mm 1 W 6 74 mm 700 750 Y 3 75 mm C A R B U R E T O R S P E C I F I C A T I O N S D A U N T L E S S V 6 See Note Make Model Designation Code Number Choke Number of Barrels Throttle Bore Main Metering Jet Production High Altitude over 5000 ft over 10 000 ft Float Level Adjustment Float Drop Adjustment Pump ...

Page 136: ... Diaphragm serviceable unit Disposable unit F U E L F I L T E R Tank unit only Left side of engine plus tank unit M O D E L L A T E M O D E L H U R R I C A N E F 4 L A T E M O D E L D A U N T L E S S V 6 A I R C L E A N E R T y p e Oil Bath Dry Type F U E L T A N K Capacity 16 gal 60 57 ltr 16 gal 60 57 ltr Between frame rails rear of vehicle Between frame rails rear of vehicle F U E L P U M P Mak...

Page 137: ...s V 6 engine Note For service information on exhaust emission control systems refer to Section F l and F2 of this manual F 2 Hurricane F4 Engine Exhaust System On the Hurricane F4 engine the exhaust and in take manifolds are separate units The intake mani fold is cast as an integral part of the cylinder head and is completely water jacketed This construction transfers heat from the cooling system ...

Page 138: ...wo cylinder banks of a Dauntless V 6 engine has an exhaust manifold On late production engines the right exhaust manifold is equipped with a heat collector manifold which supplies heated air to the air cleaner See Fig F 5 Each cylinder exhausts through its own individual port into a branch of its exhaust manifold These branches conduct exhaust gases into the main mani fold branch which connects th...

Page 139: ...o remove the exhaust manifolds disconnect the heat riser tubes and the exhaust pipe or the heat control valve from the manifold Remove the cap screws that secure the manifold to the cylinder head remove the manifold 6 Left Exhaust Pipe V6 Engine 7 Exhaust Pipe Clamp 8 Front and Rear Muffler Clamp 9 Tail Pipe Clamp Install the exhaust manifold s and torque cap screws 15 to 20 lb ft 2 07 a 2 8 kg m ...

Page 140: ...are damaged correct the condition with a thread die or replace the studs When installing the exhaust manifold there should be no bind between the manifold studs and stud holes Where such a condition is experienced the stud hole at either end of the manifold must be enlarged only enough to relieve the binding con dition Torque exhaust manifold attaching nuts 29 to 35 lb ft 4 0 a 4 8 kg m on F4 134 ...

Page 141: ...the tail pipe from the muffler To assemble position tail pipe to the muffler and secure clamps being careful to align the exhaust system so it doesn t contact body or frame Check system for exhaust gas leaks F l l EXHAUST SYSTEM SPECIFICATIONS E A R L Y M O D E L H U R R I C A N E F 4 E N G I N E E A R L Y M O D E L D A U N T L E S S V 6 E N G I N E T Y P E Muffler Type Exhaust Pipe Wall Thickness...

Page 142: ......

Page 143: ...Y MANIFOLD The air delivery manifold constructed of cold rolled steel with a zinc plating distributes the air from the pump to each of the air delivery tubes in a uniform manner A check valve is attached to the air delivery S U B J E C T P A R Air Pump Fl 17 Carburetor Air Cleaner Fl 18 R E M O V A L PROCEDURES Fl 19 Air Pump Fl 20 Anti Backfire Diverter Valve Fl 21 Air Distribution Manifold And A...

Page 144: ... or emission level problems that are peculiar to Exhaust Emission Control System equipped vehicles Fl 12 Carburetor Check carburetor number for proper application Specifications are listed at the end of this section Check the dash pot and adjust as required Proper carburetor idle mixture adjustment is im perative for best exhaust emission control The idle adjustment should be made with the en gine...

Page 145: ...ed by the relief valve is preset and is not adjustable The air pump rear cover assembly housing the pressed in inlet and discharge tubes and the pres sure relief valve are the only pump components recommended for service replacement These parts are to be replaced only when damaged as a result of handling or in the event the relief valve was tampered with Fl 18 Carburetor Air Cleaner Every 6000 mil...

Page 146: ... Tester Fl 24 REPLACEMENT PARTS Parts necessary to repair and or maintain the Exhaust Emission Control System are available through any Jeep SALES CORPORATION ware house Fl 25 WARRANTY All parts of the Exhaust Emission Control System are covered by the Manufacturer s Warranty as stated in the Warranty Service and Jeep Quality Maintenance Plan booklet Fl 26 EXHAUST EMISSION CONTROL SYSTEM DIAGNOSIS...

Page 147: ...Kilometers 3 200 9 600 19 200 28 800 38 400 48 000 Fl 28 EXHAUST EMISSION CONTROL SYSTEM CARBURETOR SPECIFICATIONS Make Models Part Number Throttle Bore Main Venturi Low Speed Jet Main Metering Jet Idle Port Nozzle Bleed in Body Pump Jet Float Level Dash Pot Setting Engine Idle R P M with Distributor Model IAY 4401A with Distributor Model IAY 4401B Carter Single Bore a n H Y F 4366S a n a 4941S 61...

Page 148: ...rol System or any of its components must not be physically altered or modified in any respect DHTfl TAG For the serviceman s guidance each vehicle equipped with exhaust emission control will have data tag permanently affixed to the radiator shroud in example VEHICLE EMISSION CONTROL INFORMATION MODEL F4 134 C I D ENGINE AT NORMAL OPERATING TEMPERATURE LIGHTS AND ALL ACCESSORIES OFF IDLE MIXTURE LE...

Page 149: ... RPM F2 2 HEATED AIR SYSTEM The heated air system on late model V6 engines consists of a manifold heat collector a heated air S U B J E C T P A R Air Pump F2 21 Intake Manifold F2 22 Carburetor Air Cleaner F2 5 F2 23 REMOVAL PROCEDURES F2 24 Air Pump F2 25 Anti Backfire Valve F2 26 Air Distribution Manifold And Air Injection Tubes F2 27 R E Q U I R E D EQUIPMENT F2 28 R E P L A C E M E N T PARTS F...

Page 150: ...aner tempera ture under 95 F 35 C the cold air door will close and the hot air door will open immediately See Fig F2 4 This is because the air bleed valve in the sensor is closed so that full manifold vacuum is applied in the vacuum motor The cold air door will remain tightly closed only a few minutes how ever As soon as the air cleaner starts receiving hot air from the heat stove the sensor will ...

Page 151: ... and tubes it is essential that the carburetor and ignition distributor be properly ad justed to specifications listed at the end of this section Road test is a factory recommended optional serv ice every 6 000 miles 9 600 km to evaluate overall performance The following procedure is recommended to assist in diagnosing performance and or emission level problems that are peculiar to Controlled Comb...

Page 152: ... determine if motor linkage is properly con nected to door or if a bind is present if link age is satisfactory then vacuum motor must be replaced Give the system a quick operational check as follows 1 Start test with engines cold air cleaner at a temperature below 85 F 29 4 C If the engine has been in recent use allow it to cool 2 Observe the cold air door before starting the engine it should be w...

Page 153: ... air door should close im mediately if engine is cool enough When cold air door starts to open in a few min utes remove air cleaner cover and read temperature gage It must read 115 F 46 C 2 0 3 If cold air door does not start to open at temperature indicated temperature sensor is defective and must be replaced F2 5 Carburetor Air Cleaner Dry Type Every 24 000 miles 38 400 km or more fre quently in...

Page 154: ...ntilator valve Also remove the PCV filter from inside the air cleaner Wash filter in suitable solvent and dry by blowing lightly with an air hose Oil with engine oil shake out excess oil Reinstall the filter After installing new valve always readjust engine idle F2 7 Replacement Procedures Should the test performed in paragraph F2 4 indicate necessary replacement of the heated air F2 8 Replacement...

Page 155: ...se into the air pump and from the pump through two outlets one for each cylinder head F2 12 AIR DELIVERY MANIFOLD The air delivery manifolds constructed of cold rolled steel with a zinc plating distribute the air from the pump to each of the air delivery tubes in a uniform manner Two check valves are included to prevent the reverse flow of exhaust gases to the pump should the pump drive fail This ...

Page 156: ...T P R Y ON T H E D I E CAST PUMP HOUSING To check the pump for proper operation remove the air outlet hose at the pump With the engine running air discharge should be felt at one of the pump outlet openings The pump outlet air pressure as determined by the relief valve is preset and is not adjustable The air pump rear cover assembly housing the pressed in inlet and discharge tubes and the pres sur...

Page 157: ...ference to re moval may be encountered due to normal carbon build up on the tubes Injection tubes removed in this manner should be replaced The injection tubes used are all of the same diam eter and length F2 28 REQUIRED EQUIPMENT Each station licensed to perform repair and main tenance on the Exhaust Emission Control System must be equipped with that equipment necessary for major engine tune up a...

Page 158: ...r condition and tension R R Replace positive crankcase ventilation valve PCV R R Check for free operation of exhaust manifold heat control valve O O O O O Clean carburetor air cleaner Oil Bath O O O O O Replace carburetor air cleaner element Dry Type O Check heated air system O O Engine tune up O O Check engine timing R O O O Adjust carburetor idle speed and mixture R O O O Perform factory recomme...

Page 159: ... tune up services performed at intervals specified in the Exhaust Emission Control System Maintenance charts For the above reasons these systems must not under any circumstances be altered to anything other than required specifications provided in this publication Further the Exhaust Emission Control System or any of its components must not be physi cally altered or modified in any respect DATA TA...

Page 160: ......

Page 161: ...ast the valve seats which are the hottest parts of the block and carry the heat away from the valves giving positive cooling of valves and seats Minimum temperature of the coolant is controlled by a thermostat mounted in the outlet passage of the engine When the coolant temperature is below thermostat rated temperature the thermostat re mains closed and the coolant is directed through the radiator...

Page 162: ...old between each of the heads and the water pump If the thermostat is closed the coolant is ported back to the pump where it is recirculated back into the pump and into the engine After the coolant heats enough to open the thermostat the coolant is directed from the water manifold through a hose to the top of the radiator and then through the radiator which acts as a heat exchanger to cool the flu...

Page 163: ...outlet at the bottom and insert the flushing gun Connect the water hose to the flushing gun to a water outlet and the air hose to an air line Turn on the water and when the radiator is full apply the air in short blasts allowing the radiator to fill between blasts Con tinue this flushing operation until the water runs clear through the top hose With the thermostat removed attach a leadaway hose to...

Page 164: ...red always install a cap of the same type and pressure rating specified It should never be altered or re placed by a plain cap A vacuum release valve Fig G 5 is employed to prevent undesirable vacuum build up when the system cools down The vacuum release valve is held against its seat under light spring pressure Vacuum in the system is relieved by the valve which opens at V2 to 1 psi 0 035 a 0 07 ...

Page 165: ...ible wire through the overflow pipe G 6 Radiator Removal and Replacement a Drain the radiator by opening the drain cock and removing the radiator pressure cap b Remove the upper and lower hose clamps and hoses at the radiator c Remove the four cap screws lock washers and flat washers that secure the radiator to the radiator body support Remove the radiator d To replace the radiator reverse the rem...

Page 166: ...e manifold The standard engine thermostat for the Hurricane F4 and Dauntless V 6 engine has a normal rating of 190 F 87 8 C and should begin to open at a coolant temperature between 180 F 82 C to 192 F 89 C and be fully open at 202 F 94 C See Fig G 7 for method of testing When the thermostat is not operating properly the engine may run too hot or too cold Overheating may damage the thermostat so t...

Page 167: ...rankshaft pulley Coolant enters the water pump at its center Centri fugal force then forces coolant radially outward through vanes of the pump impeller and backward through two discharge passages in the timing chain cover These passages conduct an equal amount of coolant to each cylinder bank water jacket This water pump has a sealed double row ball bearing and a ceramic water seal neither of whic...

Page 168: ...icle it should be washed off immediately with a good supply of cold water without wiping or rubbing Under ordi nary conditions ethylene glycol is not injurious to vehicle finishes Warning Drinking ethylene glycol antifreeze or its solutions can be harmful or fatal Do not use anti freeze containers for food or beverages A table in Par G 2 2 gives the protection obtained by the addition of various a...

Page 169: ...on should be 80 pounds 36 2 kg G l 9 Engine Overheating An engine will not be damaged by high coolant temperatures unless the coolant boils The pres surized cooling system on the Jeep vehicles raises the boiling point of the coolant solution Should overheating be encountered and the fault is be lieved to be in the cooling system check for the following a Proper coolant level See Filling Cooling Sy...

Page 170: ...r Block Sealer G 21 COOLING SYSTEM SPECIFICATIONS Radiator Cap Relief Pressure Vacuum Valve Release Thermostat Rating Starts to Open Fully Open Water Pump Type Drive Radiator Type Cooling System Capacity Without Heater With Heater Fan Number of Blades Diameter Drive Belt Angle of V Length Width H U R R I C A N E F4 7 and 15 psi 0 5 kg cm2 and 1 05 kg cm2 l A to 1 psi 0 04 a 0 07 kg cm2 190 F 87 8 ...

Page 171: ...Removal and Installation of Voltage Regulator H 72 S U B J E C T P A R Service Diagnosis H 66 Test Equipment H 68 Alternator Field Circuit Test H 73 Brush Insulation and Continuity Test H 75 Brush Removal and Inspection H 74 Rotor In Vehicle Tests H 76 A L T E R N A T O R B E N C H TESTS H 77 ALTERNATOR REMOVAL H 78 Alternator Disassembly H 80 Alternator Installation H 87 Assembling Alternator H 8...

Page 172: ...of clear water only If the acid is spilled on clothes wet it thoroughly with a weak solution of ammonia or with a solution of sodium bicarbonate or baking soda S U B J E C T P A R H O R N H 137 E L E C T R I C A L COMPONENT R E P L A C E M E N T H 150 WINDSHIPLD WIPER S Y S T E M H 141 thru 149 S E R V I C E DIAGNOSIS H 151 E L E C T R I C A L SPECIFICATIONS H 152 C a u t i o n When installing the...

Page 173: ...motor If the voltage is less than 9 volts the trouble will be found in the primary circuit If there is no voltage at all check for a break in the primary circuit possibly in the coil primary winding b To check the primary circuit turn the ignition on turn the engine until the points are closed and then measure the voltage drop across each portion of the circuit with a voltmeter Note Most voltage d...

Page 174: ...rs This leakage path will be in the form of a crack or carbon track in the cap Discon nect the spark plug wires from the cap one at a time and test each plug contact with the high voltage lead and with all other plug wires con nected Any sparking or meter drop indicates that a leakage path exists between that particular con tact and an adjacent one Testing the adjacent contacts will determine whic...

Page 175: ...or 13 Starting Motor 14 Oil Pressure Signal Switch 15 Temperature Sending Unit 16 Solenoid Switch 17 Foot Dimmer Switch 18 Stop Light Switch 19 Directional Signal Flasher 20 Fuse 21 Light Switch 22 Directional Signal Switch 23 Horn Button 24 Ignition and Starter Switch 25 Instrument Cluster A Upper Beam Indicator B Turn Signal Indicator C Instrument Lights D Oil Pressure Indicator E Charging Indic...

Page 176: ...r 23 Solenoid Switch 8 Ignition Coil 12 Right Tail and Stop Lamp 24 Temperature Sending Unit 9 Starting Motor 13 Left Tail and Stop Lamp 25 Oil Pressure Signal Switch 10 Voltage Regulator 14 Fuel Gauge Tank Unit 26 Horn 11 Instrument Cluster 15 Ignition and Starter Switch 27 Junction Block A Upper Beam Indicator 16 Horn Button whereas the Dauntless V 6 engine Delco starter ignition switch If troub...

Page 177: ...ignal Switch 24 4 Way Flasher Switch 25 Flasher 4 Way 26 Fuse 27 Main Light Switch 28 Stop Light Switch Rear 29 Fuel Gauge Tank Unit 30 Back Up Light Switch 31 Right Tail and Stop Lamp 32 Right Back Up Lamp 33 Left Back Up Lamp 34 Left Tail and Stop Lamp in which the key can be removed Turning the key to the left energizes auxiliary equipment such as windshield wipers radio and heater The turn sig...

Page 178: ...gine is mounted on the right side of the engine and is op erated by a coupling on the oil pump shaft see Fig D l which is driven by a spiral gear on the cam shaft The spark advance is fully automatic being controlled by built in centrifugal weights The Pres tolite distributor on the V 6 engine Fig H 8 is mounted at the left front of the engine on the tim ing chain cover It is driven by a spiral ge...

Page 179: ...or 31 F Temperature Indicator 32 G Fuel Gauge 33 H Instrument Voltage Regulator 34 Ignition and Starter Switch Horn Button Directional Signal Switch 4 Way Flasher Switch Flasher 4 Way Fuse Main Light Switch Stop Light Switch Rear Fuel Gauge Tank Unit Back Up Light Switch Right Tail and Stop Lamp Right Back Up Lamp Left Back Up Lamp Left Tail and Stop Lamp be burned on the horizontal face and the c...

Page 180: ...o 28 microfarads In the absence of tester check by substituting a new condenser H 13 Distributor Points a Examine the distributor points If they show wear poor mating transferred metal or pitting then new ones should be installed Clean the points with a suitable solvent and a stiff bristled brush b Check the alignment of the point for a full square contact If not correctly aligned bend the station...

Page 181: ...it is mounted separately on the outside of the distributor housing on the V6 Prestolite distributor The vacuum control unit consists of an enclosed spring loaded diaphragm linked mechanically to the distributor The air tight side of the diaphragm is connected to the intake manifold side of the carburetor Under part throttle operation the in take manifold vacuum is sufficient to actuate the diaphra...

Page 182: ... the friction spring mounted on the lower end of the drive shaft and replace it if worn or damaged Inspect rod end of vacuum advance mechanism for excessive wear Push rod into unit as far as possible hold finger tightly over nipple then release rod After about 15 seconds remove finger from nipple and notice if air is drawn into unit If not diaphragm is leaking and unit must be replaced H 18 Instal...

Page 183: ...op of the rotor it indicates the rotor is too short and needs replacing Usually when this condition is found the distributor cap segment will be burned on the horizontal face and the cap will also need replacing H 23 Condenser The condenser prolongs the life of the distributor points by preventing arcing at the contacts I t also provides a hotter spark by creating a reverse surge of current which ...

Page 184: ...and disconnect hose from vacuum advance mechanism of distributor Insert a screwdriver in upper slotted end of two distributor cap retainers Press downward and turn 90 degrees counterclock wise to release Remove cap from distributor hous ing b Make an index mark on distributor housing Fig H 14 in line with center of rotor Carefully note the direction the vacuum unit points in rela tion to engine so...

Page 185: ...washer from upper bushing Note Lubricant reservoir contains sufficient lubri cant for the life of the distributor Do not move plastic reservoir cover from housing Do not de grease bore of housing h Remove distributor primary lead and grommet from housing C a u t i o n Do not attempt to replace the shaft bushings in the housing the housing and bushings are serviced only as an assembly F I G H l 6 D...

Page 186: ...e plate e Fasten driven gear to shaft with pin Be care ful not to damage gear f Secure condenser and bracket to breaker plate with slotted screw g Install breaker point assembly over boss on breaker plate secure with two slotted screws and lock washers Apply one drop of light oil to breaker arm pivot Connect condenser and coil primary leads to breaker point assembly h Apply a small amount of high ...

Page 187: ...described in Par C 4 Inspect them for excessive burning and erosion of electrodes blistering of porcelain at the firing tip black deposits or fouling These conditions indicate that the plugs have not been operating at the cor rect temperature Note Prolonged idling just before removing and checking the plugs should be avoided as it may produce false indications Spark plug operating temperatures may...

Page 188: ...ck should be made each 6000 miles 9 600 km A visual inspection should be made of all wiring to be sure there are no broken or damaged wires Check all connections to be sure they are tight and clean Should the commutator be rough or worn the armature should be removed and the commutator turned and undercut See Par H 37 The brushes should slide freely in their holders Should they be oil soaked or if...

Page 189: ...ent is available check the field coils for current draw which should be with in the limits of 1 2 to 1 3 amperes at 10 volts for both coils A shorted coil will of course show a much higher draw while an open coil will show no draw In either case the generator output will be below normal To replace a field coil disconnect the field termin als use a heavy screwdriver to remove the field pole piece s...

Page 190: ...two coils are wound in the same direction so that when the generator is charging the battery the magnetism of the series coil increases the total magnetism When the battery discharges back through the generator the magnetism of the series coil is re versed and the magnetism of the two coils is opposed This results in a decreased pull on the armature and spring action opens the contacts 10240 F I G...

Page 191: ...and pull the arma ture down This opens the contacts and inserts re sistance in the field circuit of the generator With the field current reduced by the resistance the generator output falls and there is no longer enough magnetism to hold the contacts open As soon as the spring closes the contacts the output rises and the cycle is repeated These cycles occur at high enough frequencies to limit the ...

Page 192: ...urate indication of the operation of the volt age regulator unit connect a headphone 2000 ohm or higher between the F terminal and ground to pick up the sound of the opening and closing of the contacts The clicks should be regular and clear without irregularities or missing If the tone is not clear and regular remove the regulator cover and inspect the contacts The contacts should be flat and not ...

Page 193: ...or contacts with a 6 American Swiss cut equalling file File lengthwise and parallel to the armature and then clean the contacts with clean linen tape First draw a piece of tape that has been wet with carbon tetrachlor ide between the contacts then follow with dry tape Reset the regulator operation as in the oper ation test Par H 47 H 57 Low Battery and a Low or No Charging Rate Check all wiring fo...

Page 194: ...circuit breaker is required between the alternator and the battery Residual magnetism in the rotor field poles is negligible Therefore the starting field current must be supplied by the battery It is connected to the field winding through the ignition switch and charge indicator lamp As in the D C shunt generator the alternator voltage is regulated by varying the field current In these alternator ...

Page 195: ...ing a suspected malfunction of the alternator charging system consideration must be given to the complete electrical power plant of the vehicle including the alternator regulator ignition switch charge indicator lamp battery and all associated wiring If it is suspected that the alternator is not fully charging the battery and fulfilling the electrical requirements of the electrical system several ...

Page 196: ...omplete assembly is in sulated from the alternator housing H 70 Alternator Output Test This test excludes the regulator from the alternator system thereby isolating the problem to either the regulator or alternator Disconnect field and voltage regulator plug and connect jumper from auxiliary terminal to field terminal Start engine and run at idle Refer to Fig H 25 DC VOLTS 13403 F I G H 2 5 A L T ...

Page 197: ...erminal check charge indicator lamp and associated circuit If this voltage is not correct continue with the fol lowing test described in paragraph b Amperage Test Refer to Fig H 28 b This test evaluates complete field circuit inde pendent of voltage regulator Circuit is through brushes slip rings rotor to ground With ignition switch off current should be 2 to 2 5 amps If less than this check brush...

Page 198: ...ly charged battery and an ammeter in series with the two slip rings A rheostat is placed in series in the circuit to protect the instruments and components of the alternator Set rheostat to maximum resistance 40 ohms before making connections b Slowly reduce resistance of rheostat to zero Then take reading on ammeter With full battery voltage applied to the field coil the field current of the 35 a...

Page 199: ... e Remove the two rectifying diode heat sink as semblies and the stator as a complete unit from the rear housing by removing nuts and locknuts Note that the positive diode assembly is insulated from the alternator housing by insulated washers and insulated sleeves f The diode and stator assemblies may now be tested as outlined in Par H 83 For additional test ing Pars H 84 and H 85 or to replace a ...

Page 200: ...nce reading is not infinite or test lamp lights high leakage or a short exists between stator winding and stator In either case the diode heat sinks should be separated from the stator Par H 80 to ascertain whether the stator should be replaced Par H 84 H 84 Stator Coil Leakage and Continuity Test This test checks for shorts or leakage between stator coil windings To conduct the test the wind ing ...

Page 201: ...ler C 3858 Position the split spring washer in the front bearing housing oh top of the bearing b Install the rear bearing on the rotor shaft front end using Bearing Installer C 3935 as shown in Fig H 37 F I G H 3 7 I N S T A L L I N G R E A R R O T O R B E A R I N G 1 Rear Bearing Installer C 3935 2 Rotor Shaft C Place the rotor assembly into position in the front housing by tapping rotor shaft on...

Page 202: ...el gauge and indicator lights In START all ignition switch supplied acces sories are temporarily disconnected A connection is made to the starter solenoid lead The charge and oil indicator lamps will light until the engine is started H 90 I g n i t i o n S w i t c h R e m o v a l a Remove the bezel nut and pull back the main switch body Lower the switch body from under the instrument panel so that...

Page 203: ...operation may be caused by a dirty commutator or worn brushes The com mutator cannot be cleaned while the starting motor is mounted on the engine and it will be necessary to remove it and proceed as for an overhaul Should 7 Ignition Switch 8 Solenoid Wire 9 Starter 10 Solenoid 11 Connector Strap the commuator be rough or worn it should be removed for cleaning and reconditioning H 96 Overhaul Proce...

Page 204: ...ed to the field coil should be unsoldered and the loop in the field coil lead should be opened Insert the new brush pigtail to its full depth in the loop The new brush lead should be tightly clinched in the terminal and then soldered to make a strong low resistance connection H 99 Commutator Check the commutator for wear and discoloration If the commutator is rough or worn the armature should be r...

Page 205: ...t for open circuits place the probes on the field coil terminal and on an insulated brush If the light does not light the coil is open circuited H 102 Brush Holder Inspection Using test probes touch the insulated brush holder with one probe and a convenient ground on the commutator end head with the other probe If the lamp lights it indicates a grounded brush holder H 103 S t a r t i n g Motor Rea...

Page 206: ...Bendix Folo Thru Drive is designed to over come premature demeshing of the drive pinion from the flywheel ring gear until a predetermined engine speed is reached See Fig H 43 No repairs or adjustments are possible on this drive and a complete new unit must be installed if trouble develops H 106 Lubrication of F o l o T h r u Drive A periodic cleaning and relubrication of the drive is advisable the...

Page 207: ...E F 4 F I G H 4 6 P R E S T O L I T E S T A R T E R A N D S O L E N O I D V 6 E N G I N E switch terminals The voltage drop should not exceed 05 volts per 100 amperes Should it be impossible to file the switch contact plates to obtain a clean full surface contact the switch should be replaced Current model starting switches are of the solenoid type mounted directly on the starting motors This type...

Page 208: ... nut and disconnect field lead which passes through grommet at top of motor from motor terminal of solenoid Remove two thru bolts from motor Remove commutator end frame and field frame assembly from solenoid and drive assembly e Pull out pivot pins of brush holders and remove each of two brush holder and spring assemblies from field housing Remove screws which attach brushes and leads to holders d...

Page 209: ...noid coil as follows a Remove screw from motor terminal of solenoid and bend field coil leads away from terminal Con nect terminal to ground with a heavy jumper wire See Fig H 48 b Connect a 12 volt battery a high current vari able resistance and an ammeter of 100 amperes capacity in series between S terminal of solenoid and ground battery negative is to be connected to ground Connect a heavy jump...

Page 210: ... armature assembly Lubricate bearing in com mutator end frame with silicone grease and position end frame to field frame so that armature shaft enters bearing Secure field frame and end frame to drive housing with two thru bolts Connect field leads to motor terminal of solenoid with connect ing nut j Whenever the starting motor is disassembled and reassembled the pinion clearance should be checked...

Page 211: ...ircuit in the field coils H 120 Locked Armature Test This test requires a D C voltmeter with range ap propriate to read voltages in a 12 volt circuit a D C ammeter with maximum range of several hundred amperes a high current variable resistance a clamping fixture to lock together the motor shaft and case and a fully charged 12 volt battery a Connect a jumper lead between S terminal and large batte...

Page 212: ...er bar be sure the curved segment is closest to the fuel gauge Should only one of the two gauges register incor rectly check the lead wire from the gauge to the sending unit for shorts or open connections Next disconnect the gauge from the sending unit and connect the gauge to a new fuel tank sending unit which has been grounded to the vehicle If the gauge registers incorrectly when operating the ...

Page 213: ...uction vehicles are equipped with two stop light switches that operate independently of each other Both switches are located along the left side of frame in the front and rear brake lines C a u t i o n Do not apply the brakes while making this exchange as air may enter the hydraulic line Bleed the brakes after replacing the switch Fig H 54 shows the wiring of the stop light circuit 11500 F I G H 5...

Page 214: ...Position the vehicle perpendicular to the screen and with the front head lamps directly over the reference line b Locate the middle tape on the screen so that it is aligned with the center line of the vehicle c Equalize all tire pressures d Rock the vehicle from side to side to equalize springs and shock absorbers e Measure the distance between vehicle head lamp centers Then position marker tapes ...

Page 215: ...to the right of the lamp center line See Fig H 60 d Cover the lamp that has been aimed and aim the other lamp using the same procedure e Carefully reinstall the head lamp doors H 133 Parking a n d T u r n Signal L i g h t The parking lights are mounted in the radiator guard panel just below the headlights These lights are on only when the main switch control knob is pulled out to the first notch T...

Page 216: ...ct cap from the steering wheel nut This will expose the contact tip of the horn wire Pull the wire out of the steering column from the top Refer to Fig H 62 H 13S D i r e c t i o n a l S i g n a l s Fig H 63 shows the wiring of a composite direction al signal circuit The most frequent causes of failure in the directional signal system are loose connec tions and burned out bulbs A flashing rate app...

Page 217: ...he vehicle The wiper motors are operated and controlled by a switch located on the instru ment panel Current production vehicles with stationary wind shield have a two speed electric windshield wiper motor mounted below the windshield outside the vehicle on the driver s side The wiper motor switch is located on the instrument panel to the left of the steering column H 142 Two Speed Wiper Motor The...

Page 218: ... Remove parking brushes spring and bowed washer from gear assembly i Remove the two through bolts and mounting bracket j Remove the magnet housing armature and end cap as an assembly k Tap end of armature shaft to loosen end cap assembly and remove cap from armature shaft Be careful not to lose thrust disc which is in end cap bearing bore I Remove armature from magnet housing Care should be taken ...

Page 219: ...te and Delco Remy Components a Some Prestolite and Delco Remy electrical components may be intermixed on a vehicle as an approved production practice No attempt should be made to convert to a complete Prestolite or Delco Remy system Prestolite components should be replaced by Prestolite components and Delco Remy components should be replaced by Delco Remy components insofar as availability of re p...

Page 220: ...or Badly Worn Belt Misaligned Belt or Pulley Loose Pulley Worn Bearings Shorted Rectifiers Generator Low Charging Rate Dirty Commutator Poor Brush Contact Regulator Improperly Adjusted High Resistance in Charging Circuit Ground Strap Engine to Frame Broken Loose or Dirty Terminals Slipping Generator Belt Worn Out Brushes Weak Brush Spring T e n s i o n Out of Round Commutator PROBABLE R E M E D Y ...

Page 221: ... Install New Brushes Weak Brush Spring Tension Replace Worn Bearings Replace Burned Starter Switch Contacts Replace Switch Will Not Turn Engine Open Circuit at Starter Correct Solenoid Open or Stuck Replace Solenoid Starter Switch Defective Replace Switch Starter Drive Broken or Stuck Repair or Replace Battery Discharged Recharge Battery Distributor Hard Starting Distributor Points Burned or Pitte...

Page 222: ...n Button and Battery Clean and Tighten Battery Low or Dead Check Battery Contact Points Burned or Broken Off Replace Parts Necessary Horn Sounds Unsatisfactory Tone Poor Electrical Connection Check Connections at Horn Horn Button Battery Battery Low Check with Hydrometer Loose Cover and Bracket Screws Tighten Bracket Bolts at Horn Voltage at Horn too High or too Low Check with Voltmeter 222 ...

Page 223: ...60 1 225 Engine Compartment Right Rear Prestolite GJP 7402A Negative 35 amp C V Regulator 003 to 010 0 076 a 0 25 mm 2 18 to 36 oz 510 a 1020 gr Prestolite VBO 4201E 4A Vibrator 12 6 to 13 6 1325 3 to 5 amp 14 2 to 14 4 36 amp max Motorola A12 N W 526 Negative 35 amp 1 7 to 2 3 amp 1 mfd Motorola R 2 K 1 Transistor Prestolite MDU 7004 32 to 40 oz 907 a 1134 gr 70 F 21 C 295 4 6 lb ft 0 83 kg m 70 ...

Page 224: ... L o c a t i o n Crankshaft Pulley Crankshaft Pulley Crankshaft Pulley Csankshaft Pulley Firing Order 1 3 4 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 S P A R K P L U G S Make Champion A C A C or Champion A C or Champion J8 44S 44S or U J 12Y 44S or U J 12Y Thread 14 mm 14 mm 14 mm 14 mm Thread Reach Vz 9 47 mm 9 47 mm 9 47 mm V8 9 47 mm Gap 030 0 762 mm 035 0 900 mm 035 0 900 mm 035 0 900 mm L A M P B...

Page 225: ... Parts 1 16 thru 1 20 Pressure Plate Reassembly 1 21 thru 1 23 Clutch Lever Adjustment 1 24 Clutch Fitxure 1 26 C L U T C H THROWOUT R E L E A S E BEARING 1 25 S E R V I C E DIAGNOSIS 1 28 C L U T C H SPECIFICATIONS 1 29 C L U T C H ADJUSTING F I X T U R E DATA 1 30 F I G I 1 C L U T C H L I N K A G E AND A D J U S T M E N T C R O S S S H A F T T U B E A N D L E V E R T Y P E 1 Clutch Release Bear...

Page 226: ...sted causing the bearing to become dry noisy or will seize resulting in clutch finger or diaphragm wear The clutch must be properly adjusted so that the release bearing is free of the clutch fingers or diaphragm at all times except when the clutch pedal is depressed Excessive clutch slippage often occurs when the vehicle is overloaded the vehicle load is applied too quickly or when the pressure of...

Page 227: ...e The auburn clutch driving pressure plate assembly Fig 1 3 has three pressure springs and three levers or fingers 1 5 Clutch Removal When necessary to remove the clutch follow the procedures outlined in Section J for the removal of the transmission and transfer case from the vehicle Then remove the flywheel housing and use the following procedures for removing the clutch assembly Note The F4 engi...

Page 228: ...bushing is worn or damaged it should be removed using a pilot bushing remover Screw the tapered end of the tool into the damaged bushing allowing the tool to cut its own threads until a solid grip is obtained Insert the puller screw and rotate it until bushing is forced out of flywheel Fig 1 6 or crankshaft To install a new bushing slide the bushing onto the end of a pilot bushing installing and b...

Page 229: ...waves to provide springs between the plate facings and cushion engagement of the clutch A molded facing is riveted to each side of every segment When the clutch is fully released the waved segments cause the facings to spread approximately 045 1 14 mm Pressure plate movement provides an additional clearance of approximately 030 0 76 mm to assure full release of the driven plate See Fig 1 8 The dri...

Page 230: ...E PLATE AND DISC BORG BECK V6 Late Models The Borg Beck clutch is a single plate dry disk type It provides smooth engagement of engine power to the wheels The clutch consists of a pres sure plate assembly with pressure springs and release levers and driven plate assembly The driven plate assembly uses spring center vibration neutralizes and two flexible facings The clutch driven plate is spring cu...

Page 231: ...nterfere with the block Place a wood block across the top of the cover so that it rests on the spring bosses and does not interfere with the eyebolt adjusting nuts as shown in Fig 1 12 Compress the clutch cover in the press until the clutch release levers are free Remove the adjust ing nuts Release the press slowly to prevent the springs from flying out Remove felt grease pads Caution When relievi...

Page 232: ...sively worn facings should be replaced The clutch disc must be in stalled with the long end of the hub toward the transmission 1 20 Inspect Transmission Clutch Shaft Slide the clutch driven plate onto the transmission clutch shaft to make sure that it is free on the splines If the splines on the transmission clutch shaft are burred remove the burrs with a fine file or stone If the movement of the ...

Page 233: ...crews in rotation one to two turns at a time to avoid distortion of the cover F I G 1 18 CLUTCH H E I G H T A D J U S T M E N T Each lever should be depressed several times be fore checking This will seat the levers in their operating positions as shown in Fig 1 17 Place the gauge on the hub as shown in Fig 1 18 To adjust the levers turn the lever adjustment nut until the levers are to 6 0 93 a 1 ...

Page 234: ... and tap six equally spaced holes 3 8 16 thread on the l l s 8 29 6 cm dia meter bolt circle and 18 thread on the 10 27 1 cm diameter bolt circle Drill and tap six Jf6 18 thread holes as indicated on the 9 24 10 cm diameter bolt circle Hole spacing and bolt circle tolerances should be held to plus or minus 002 050 mm Countersink all holes to a depth of 8 mm Drill and tap the holes all the way thro...

Page 235: ... If disassembled install pressure plate in the cover assembly lining up the groove on its edge with the groove on the edge of the cover Install pressure plate retracting springs and the three drive strap to pressure plate bolts and lock washers Torque bolts 11 lb ft 1 51 kg m Note The diaphragm type clutch assembly is fac tory calibrated and requires no adjustment before installation Refer to Par ...

Page 236: ...e difficulty Make certain that the clutch linkage is tight and in proper adjustment Note Should a noise occur at the clutch control lever and tube assembly when the clutch pedal is depressed remove the existing washer located inside the tube at the end of the ball stud mounted on the transfer case and add a second dust shield over the ball stud as shown in Fig 1 25 236 ...

Page 237: ...ace 1 29 CLUTCH SPECIFICATIONS E N G I N E H U R R I C A N E F 4 D A U N T L E S S V 6 D A U N T L E S S V 6 E A R L Y M O D E L S L A T E M O D E L S Pressure Plate Auburn G M Borg and Beck Type Single Dry Plate Single Plate Dry Disc Single Plate Dry Disc No of Springs 3 Diaphragm Type Coil Spring Type 9 Total Plate Pressure 1150 lb 521 6 kg 1600 lb 725 kg 1765 lb 800 kg Driven Plate Make Auburn ...

Page 238: ......

Page 239: ... side of the transmission housing The remote control lever shifts the transmission gears through remote control rods attached to the adjusting levers of the shift shafts protruding from the left side of the transmission housing Poppet balls and springs retain the transmission gears in mesh and an interlocking mechanism prevents shifting into two gears at the same time J 3 T r a n s m i s s i o n R...

Page 240: ... hole in the clutch lever aligns with hole in the housing Assemble the lower clutch lever assembly in hous ing until faces of clutches contact then back off not more than one half turn which should bring the aligning hole in the lever in line with the hole in the housing If the one half turn does not bring the alignment hole in proper position it will be necessary to grind off square with axis not...

Page 241: ... control rods d Remove the set screw from the transfer case shift lever pivot pin Remove the pivot pin shift levers and shift lever springs On models CJ 5A and CJ 6A remove pivot pin cotter key and the adjusting rod attaching nut to remove shift lever See Fig J l e If the vehicle is equipped with power take off remove the shift lever plate screws and lift out the lever f Disconnect the front and r...

Page 242: ...Clutch Hub 43 Main Shaft Pilot Bearing Roller J 7 Separating T r a n s m i s s i o n a n d T r a n s f e r Case a Remove the six screws and lockwashers attach ing the transfer case rear cover and remove the cover Or should the vehicle be equipped with a power take off remove the power take off shift unit which replaces the cover b Remove cotter pin nut and washer which hold the transfer case main ...

Page 243: ... Jeep U N I V E R S A L S E R I E S S E R V I C E M A N U A L J 243 ...

Page 244: ... Shoe 25 Mainshaft Bearing Spacer 26 Mainshaft Bearing Adapter 27 Mainshaft Bearing 28 Mainshaft Washer 29 Mainshaft Nut 30 Lock Plate 3 1 Countershaft 32 Steel Thrust Washer 33 Bronze Thrust Washer 34 Countershaft Bearing Spacer 35 Countershaft Bearing Center Spacer 36 Countershaft Bearing Rollers 37 Reverse Idler Gear Shaft 38 Reverse Idler Gear Assembly 39 Countershaft Gear 40 Countershaft Fron...

Page 245: ... M I S S I O N C A N E S H I F T 1 Bearing Retainer Screws 2 Main Drive Gear Bearing Retainer 3 Bearing Retainer Oil Seal 4 Bearing Snap Ring 5 Main Drive Gear Snap Ring 6 Main Drive Gear Bearing 7 Front Bearing Oil Retaining Washer 8 Main Drive Gear 9 Pilot Roller Bearing 10 Shift Rail Cap 11 Poppet Ball 12 Poppet Spring 13 Lock Washer 14 Shift Housing Bolt 15 Control Housing 16 Interlock Plunger...

Page 246: ...ssembly of the trans mission on those models with a cane shift n On CJ 5A and CJ 6A models equipped with a remote shift transmission inspect the poppet and interlock assembly which floats between the shift lever assemblies described in Par J 9 F I G J 9 C O U N T E R S H A F T G E A R B E A R I N G A R B O R F I G J l 0 C O U N T E R S H A F T B E A R I N G S P A C E R S J 9 Transmission Interlock...

Page 247: ...166 with loading sleeve as shown in Fig J 9 and J 10 Place the spacer inside the hub and insert the special tool in the spacer Place a washer at each end of the spacer and load a set of bearing rollers at each end Then add a washer a set of bearing rollers and finally another washer at each end to complete the as sembly Place the countershaft gear assembly in the case but do not install the counte...

Page 248: ...ove the clutch hub and synchronizer assembly through the top m Remove the low and reverse sliding gears and the constant mesh gear and main shaft in one unit through the top n Remove the countershaft gears through the top Take care not to misplace the twenty rollers at each end of the long spacer as well as the two thrust washers and the two roller spacer bearings o Using a soft drift drive the re...

Page 249: ...case i Enter the main shaft bearing in the case and assemble the shaft in position j Install the front bearing retainer k For ease in installing the countershaft turn the transmission case over to allow the gears to mesh With the countershaft thrust washers correctly positioned start the countershaft through the rear of the case with the lock plate slot toward the rear and the slot in alignment wi...

Page 250: ...ress the shaft through the gears and into the front of the case forcing out Tool W 193 I Locate the lock plate in the slots of the reverse idler gear shaft and countershaft Tap the two shafts until lock plate is tight against case m Install rear bearing snap ring and rear main shaft bearing on shaft n Attach rear bearing retainer and gasket to the transmission case Tighten cap screws evenly and se...

Page 251: ...T 1 4 A Refer to Fig J 13 a If the transfer case is attached separate it from the transmission by removing the five capscrews and lockwashers b Remove cane shift housing cover and gasket from top of transmission case The shift housing cover can be disassembled if necessary at this point by removing the shift rails poppet balls springs and shift forks Refer to Fig J 14 c Remove nut and flat washer ...

Page 252: ... spacer washers bear ing rollers and spacer from the countergear hub assembly for inspection I Using Tool W 336 drive the reverse idler shaft rearward out of the case Remove reverse idler gear washers and roller hearings as an assembly Refer to Fig J 21 m Remove the clutch hub snap ring and the second third synchronizer assembly from the main shaft Refer to Fig j 22 V r 12852 F I G J 2 2 R E M O V...

Page 253: ...ssembly parts f Assemble synchronizer in reverse order of dis assembly making certain the two synchronizer spring openings are installed 120 of each other with spring tension opposed Low Synchronizer Unit Refer tc Fig J 25 The low synchronizer assembly is serviced in the same manner as second third with exception of one synchronizer spring 12853 F I G J 25 L O W S Y N C H R O N I Z E R A S S E M B...

Page 254: ...L L E D 1 Countershaft Gear 2 Countershaft Bearing Rollera 3 Countershaft 4 Spacers 5 Center Spacer F I G J 2 8 L O C K P L A T E I N S T A L L A T I O N 1 Reverse Idler Shaft 2 Lockplate 3 Countershaft gear shaft Press shaft through the gear hub as sembly and into the front of the case forcing out Tool W 335 d Locate the lockplate in the slots of the reverse idler shaft and countershaft Tap the t...

Page 255: ... when driving bearings into position as shown in Figs J 31 and J 32 m Install main drive gear and mainshaft bearing snap rings Note The mainshaft bearing snap ring is 010 0 254 mm thicker than the main drive gear bear 12882 F I G J 3 1 I N S T A L L I N G M A I N D R I V E G E A R B E A R I N G 1 Tool SP 5364 Short Driver 2 Tool W 334 Thrust Yoke 3 Tool W 331 Long Driver 4 Wood Block F I G J 3 2 I...

Page 256: ...t in the retainer housing and gasket are aligned Install the three ferry type screws and washers Refer to Fig J 34 q Install the transmission case cover gasket p Position the transmission gear train and shift cover housing assembly in neutral Enter the shifter forks into the clutch sleeves and align cover case and gasket holes Install capscrews and lock washers and torque 8 to 15 lb ft 1 1 a 2 1 k...

Page 257: ...ne Tighten Front Retainer Replace J 21 TRANSMISSION SPECIFICATIONS H U R R I C A N E F4 E N G I N E 3 S P E E D Vehicle CJ 3B CJ 5 CJ 5A CJ 6 CJ 6A DJ 5 DJ 6 Make Type Speeds Ratios First Second Third Fourth Warner T90C Synchronous Mesh 3 Forward 1 Reverse 3 339 to 1 1 551 to 1 1 000 to 1 Warner T96 Synchronous Mesh 3 Forward 1 Reverse 2 605 to 1 1 630 to 1 1 000 to 1 Reverse Interlock Poppet Clea...

Page 258: ......

Page 259: ... Arm 8 C Washer 9 Reverse Shifting Arm Pivot 1 0 O Ring 11 Reverse Idler Gear Assembly 12 Snap Ring 1 3 Thrust Washer 14 Sleeve 15 Bearing Rollers 16 Spacer 17 Reverse Idler Gear 18 Pipe Plug 19 Countershaft Gears 20 Bearing Rollers 21 Spacer 22 Spacer 23 Thrust Washer 24 Bellhousi ng to Transmission Adapter Plate 25 Bearing Retainer 26 Bearing Retainer Bolt 27 Bearing Retainer Lockwasher 28 Beari...

Page 260: ...smissions are the same J1 2 Four Speed Transmission Removal Use the procedure outlined under the heading TRANSMISSION R E M O V A L Section J Par J 6 F I G J l 2 F O U R S P E E D T R A N S M I S S I O N M A I N D R I V E G E A R 1 Snap Ring 3 Bearing 5 Main Drive Gear 2 Snap Ring 4 Washer 6 Bearing Rollers F I G Jl 3 T 98 F O U R S P E E D T R A N S M I S S I O N M A I N S H A F T 1 Blocking Ring...

Page 261: ...ain drive gear ball bearing 1436S i Hub Gear izer Assembly ironizer Assembly i Remove the oil slinger j Remove the snap ring from the outer bearing race of the transmission mainshaft ball bearing k With a bearing puller remove the mainshaft ball bearing Note It may be necessary to drive the mainshaft rearward by striking the end of the main drive gear with a lead hammer to get sufficient clearance...

Page 262: ...dler gear shaft out of the housing and gear Lift the reverse idler gear assembly from the transmission case y To remove the countershaft use a heavy brass drift and drive the countershaft toward the rear of the transmission case When the countershaft end is just about even with the inside of the trans mission case use a dummy shaft to force it the remainder of the way Since a dummy shaft is a F I ...

Page 263: ...he plunger and spring until the C washer groove just clears the end of the casting Remove the C washer J 1 5 4 speed T r a n s m i s s i o n Reassembly Refer to Fig Jl 1 Assemble the unit in the reverse order of dis assembly noting the following points a Assemble the countershaft assembly with the fabricated dummy shaft The bronze front thrust washer and the steel backed bronze rear thrust washer ...

Page 264: ...marks made at the time of disassembly Install snap ring h Install main drive gear assembly with roller bearings in place in front of case Install mainshaft F I G J l 8 S E C O N D S P E E D G E A R A S S E M B L Y T 9 8 O N L Y 1 Spacer 3 Rubber Band 2 Bearing Rollers 4 Thrust Washer assembly through top of case making sure roller bearings are not knocked out of place i Temporarily install main dr...

Page 265: ...ew heads do not protrude beyond the adapter plate face or interfere with transfer case fitting tightly against rear adapter plate When installing transfer case gear on the trans F I G J l 1 0 C O R R E C T O I L S E A L P O S I T I O N mission rear splined drive shaft tighten the large gear nut securely and insert cotter pin Sink cotter pin well into nut slots so it will clear P T O drive J1 8 Ada...

Page 266: ...n Replace Gears Shifting Shoe Bent Replace Shoe Lack of Lubrication Drain and Refill G r e a s e L e a k into Bellhousing Gasket Broken Front Bearing R e t a i n e r Replace Transmission Main Drive Gear Oil Seal Replace Jl 10 TRANSMISSION SPECIFICATIONS H U R R I C A N E F 4 E N G I N E 4 S P E E D Vehicle CJ 5 CJ 6 Warner T98A Type Synchronous Mesh 4 Forward 1 Reverse Ratios First 6 398 to 1 Seco...

Page 267: ...ver right hand lever has three positions low neutral and high The forward position low gives low range 4 wheel drive The center position neutral dis engages all power to the wheels and is used for stationary power take off operations A built in in terlock prevents shifting into low range 2 wheel drive This feature protects the rear axle from over load K 2 Removal of Transfer Case The transfer case...

Page 268: ...ission 2 8 Pivot Pin 29 Lubrication Fitting 3 0 Set Screw 3 1 Oil Seal 32 Front Yoke 3 3 Gasket 34 Bolt 3 5 Lockwasher 3 6 Shift Rod 37 Shift Fork 3 8 Shift Fork 3 9 Filler Pipe Plug 40 Mainshaft Gear 41 plain Washer 4 2 Thrust Washer 4 3 Intermediate Gear 4 4 Snap Ring 4 5 Bearing 46 Nut 4 7 Washer 4 8 Output Clutch Shaft 4 9 Output Clutch Gear 50 Snap Ring 51 Thrust Washer 5 2 Output Shaft Gear ...

Page 269: ...hift Fork 3 1 Underdrive and Direct Shift Fork 3 2 Filler Plug 3 3 Mainshaft Gear 34 Mainshaft Washer 35 Thrust Washer 36 Intermediate Gear 37 Bearing Shaft Snap Ring 38 Output Clutch Shaft Bearing 39 Companion Flange Nut 40 Plain Washer 4 1 Output Clutch Shaft 4 2 Output Clutch Shaft Gear 43 Output Shaft Gear Snap Ring 4 4 Thrust Washer 45 Output Shaft Gear 46 Output Shaft Sliding Gear 47 Pilot B...

Page 270: ...of the gear shaft e Remove the intermediate gear two thrust washers needle bearings and spacers thru the bottom of the case f Remove the poppet plugs springs and balls on both sides of front bearing cap Shift front wheel shift lever to engaged position shaft forward g Remove the screws lockwashers holding the front bearing cap Remove the cap as an assembly including the clutch shaft bearing clutch...

Page 271: ...rward as outlined in Par K 3f b Remove yoke oil seal with Tool W 251 as shown in Fig K 7 Remove shift rod oil seals with Tool W 176 as shown in Fig K 8 c Remove the front bearing cap assembly as outlined in Par K 3g F I G K 9 S H I F T R O D O I L S E A L I N S T A L L E R 1 Driver 2 Thimble 3 Oil Seal d Remove the set screw from shifting fork and shifting rod The clutch gear and shifting fork can...

Page 272: ... 2 86 cm diameter intermediate shaft and caged needle bearings When installing the intermediate gear in early production transfer cases insert the bearings in the gear support the front thrust washer with Pilot Pin Tool W 192 Fig K 10 position the gears and rear thrust washer and insert the shaft from the rear of the case Late production transfer cases were equipped with a 1 Vi 3 18 cm diameter in...

Page 273: ...the transmission was removed from the vehicle lubricate the pilot bearing and also lubricate the transmission and transfer case as outlined in the Lubrication Section Be sure that the clutch pedal has 19 05 mm free travel as outlined in the Clutch Section K 8 Transfer Case Linkage Adjustment Adjust the link to provide x h 12 7 mm clear ance between the floor pan and the shift lever bend when opera...

Page 274: ......

Page 275: ...he shafts dented or bent shafts and loose attaching bolts L 2 Needle Bearing a n d T r u n n i o n Universal J o i n t Each shaft is equipped with a splined slip joint at one end to allow for variations in length caused by vehicle spring action Some slip joints are marked with arrows at the spline and sleeve yoke Fig L 3 When installing align the arrows in the same plane If unmarked with arrows al...

Page 276: ...face about i 0 8 mm smaller in diameter than the hole in the yoke arm and drive out the bearing Lift the journal out by sliding to one side Clean all parts and check for wear L 6 U Bolt Type Assembly Wash all parts in cleaning solvent and inspect the parts after cleaning Replace any parts that indicate extensive wear It is advisable to install new gaskets on the journal assembly regardless of the ...

Page 277: ...ng rod con nects the bell crank to the steering gear arm The divided tie rod is adjustable and the toe in of each front wheel is adjusted independently Camber and S U B J E C T P A R R E A S S E M B L Y AND B E A R I N G PRELOAD M 9 A X L E SHAFT INSTALLATION M l l FRONT A X L E I N S T A L L A T I O N M l2 Turning Angle Adjustment M 14 Steering Tie Rod and Beilcrank M l3 2 WHEEL D R I V E FRONT A...

Page 278: ...d open The front wheel bearings should be checked every 12 000 miles Refer to Section Q Front wheel toe in is adjustable by lengthening or shortening the tie rod However standard caster and camber of the front wheels are built into the axle Wheel caster can be adjusted by placing tapered shim plates or wedges between the springs and spring seats welded to the axle housing Steering geometry and fro...

Page 279: ...e oil seal F I G M 5 W H E E L B E A R I N G N U T W R E N C H 1 Tool W 144 g Remove the hydraulic brake tube and the brake backing plate screws h Remove the spindle i Remove the axle shaft and universal joint as sembly M 6 Removing a n d Overhauling Differential Adjustment and overhaul of the front axle differen tial assembly is the same as that of a full floating type rear axle Information cover...

Page 280: ... in cleaning solvent and inspect the parts after cleaning Replace any parts that indicate extensive wear e Pack the bearing cones one third full of lubri cant and install the rollers f Insert the bearings into the end yoke arm and seat them firmly against the bearing shoulders g Holding the bearings in a vertical position to prevent the needles from dropping out reassemble the joint in the reverse...

Page 281: ...ng preload should be 12 to 16 lb 5 43 a 7 24 kg with the oil seal removed Remove or add shims to obtain a preload within these limits F I G M 9 S P I N D L E P I N B E A R I N G C U P D R I V E R 1 Tool W 138 F I G M 1 0 T U R N I N G A N G L E STOP S C R E W 1 Stop Screw M 10 Replacing Steering K n u c k l e Oil Seal Remove the old steering knuckle oil seal by remov ing the eight screws which hol...

Page 282: ...ow ing operations a Torque spring clip plate U bolt nuts securing the axle to the front springs see Par M 4 b Adjust and bleed the brakes see Section P c Check axle lubricant level and fill as necessary see Section B d Check front end wheel alignment see Section O e Check wheel turning angle Refer to Par M 14 M 13 Steering T i e Rod a n d Bell C r a n k These parts of the front axle are covered in...

Page 283: ...lic hoses at the connections between front brake lines and flexible hoses f Support the axle assembly on a jack ready for removal g On vehicles with the springs slung over the axle remove the nuts from the spring to axle U bolt clips remove the spring clip plates and slide the axle as sembly from underneath the vehicle On vehicles with the springs slung under the axle remove the nuts from the spri...

Page 284: ...brake backing plate g Remove the tapered steering knuckle pin lock h Remove the upper steering knuckle expansion plug on early models or the lock spring on late models i Drive the Steering Kunckle Pin and lower ex pansion plug out through the bottom When the spindle is disassembled do not lose the spacing shim between the upper face of the axle and the spindle j Remove the thrust bearing and bushi...

Page 285: ...n Bearings Rough Axle Noisy o n C oast Excessive Back Lash at Ring and Pinion Gears End Play in Pinion Shaft Rough Bearing Axle Noisy o n Coast a n d Pull Ring and Pinion Adjusted too Tight Pinion Set too Deep in Ring Gear Pinion Bearing Loose or Worn B a c k L a s h Axle Shaft Universal Joint Worn Axle Shaft Improperly Adjusted Worn Differential Pinion Washers Worn Propeller Shaft Universal Joint...

Page 286: ...ential Drive Pinion Offset Number of Differential Pinions Gear Ratio F4 Engine Standard Optional V 6 Engine Standard Optional Ring Gear Pitch Diameter Pinion Adjustment Pinion Bearing Adjustment Dana 27AF 2000 lb 907 kg Full floating Hypoid Gears Spicer Cardan Cross 12 to 16 lb 5 44 a 7 25 kg 1 38 35 05 mm 2 4 27 1 5 38 1 3 73 1 4 88 1 7 12 19 05 cm Shim Shim Clark 130097 2000 lb 907 kg Reverse El...

Page 287: ...les are used See Specifi cations Chart Par N 38 for description and ratio The axle model number is cast into the housing as F I G N l A X L E M O D E L I D E N T I F I C A T I O N illustrated in Fig N l A metal tag under two ad jacent differential housing cover cap screws is stamped to identify the number of teeth in the drive gear and pinion and notes the axle ratio A R E A R A X L E ASSEMBLY INS...

Page 288: ... R e Use Wheel Hub Puller C 319 to remove the wheel hub as shown in Fig N 4 f Remove the screws attaching the brake dust protector grease and bearing retainers brake as sembly and shim to the housing g Remove the hydraulic line from the brake as sembly h Remove the dust shield and oil seal i Using Tool C 637 and Adapter Tool SP 342 remove the axle shaft bearing cone roller and cup as shown in Fig ...

Page 289: ... sharp tool and prying it out d Using access hole in axle shaft flange remove 30 29 F I G N 7 S E M I F L O A T R E A R A X L E A S S E M B L Y F L A N G E D S H A F T 1 Differential Bearing Cup 2 Differential Bearing 3 Shims 4 Differential 5 Ring Gear and Pinion 6 Pinion Inner Bearing 7 Pinion Inner Bearing Cup 8 Pinion Shims 9 Axle Housing 10 Breather 11 Pinion Outer Bearing Cup 12 Pinion Outer ...

Page 290: ...g through the outboard seal by the re tainer plate The outboard seal wipes on the rotat ing axle shaft and at the same time functions as a static seal to prevent lubricant from escaping be tween the housing and the seal outside diameter It s important to note that the seal serves also as a spacer or filler in the clamp up of the bearing in the axle housing Note All Unit Bearings are manufactured w...

Page 291: ...al in the axle housing and in the cavity between the inboard grease seal and the bearing The bottom one third of this cavity should be filled with grease g Install the axle shaft and bearing assembly into axle housing as described in Par N 8 This com pletes the servicing of the axle shaft Unit Bearing H 7 Unit Bearing Removal If it is necessary to remove the Unit Bearing as sembly from the axle sh...

Page 292: ...g the axle flange f Install the new bearing retainer ring on the axle shaft g Using puller tool W 343 press the new axle shaft bearing and retainer ring on the axle shaft simultaneously Tighten puller bolts alternately until the bearing and retainer ring are properly seated against the shaft shoulder Refer to Fig N 15 and N 16 14154 F I G N 1 5 I N S T A L L I N G A X L E S H A F T B E A R I N G 1...

Page 293: ...ction procedure is as follows a Drain lubricant and remove housing cover and gasket b Clean the differential parts thoroughly with sol vent c Carefully inspect all parts Should it be determined by inspection that the differential requires overhauling the axle must first be removed from the vehicle Note All service replacement axle assemblies are shipped from the factory without lubricant in the di...

Page 294: ...ase loose using pry bars at the heads of the ring gear bolts and carrier casting f Remove spreader immediately to prevent the possibility of the carrier taking a set g Remove the screws holding the ring gear to the differential case h With a small punch as shown in Fig N 20 drive out the lock pin F I G N 2 0 R E M O V I N G L O C K P I N i Remove the differential shaft and thrust block Note Thrust...

Page 295: ... and outer bearing cups from the housing a Using a brass drift drive the pinion inner bear ing cup and shims from the housing Even if mutilated these shims should be kept for proper assembly of differential b Using a brass drift drive the outer pinion cup from the housing N 15 Cleaning and Inspection a Clean all parts in fast evaporating mineral spirits or a dry cleaning solvent and with the excep...

Page 296: ...ustment Refer to Fig N 3 and N 7 Adjustment of the pinion is accomplished by the use of shims placed between the inner bearing cup and the axle housing and between the pinion shoulder and the outer bearing The shims behind F I G N 2 5 I N S T A L L I N G O U T E R B E A R I N G C U P F I G N 26 PINION B E A R I N G I N S T A L L I N G S L E E V E 1 Sleeve the inner bearing cup adjust the position ...

Page 297: ...other tools to rest on it Treat the C type fixture tool carefully as a precision in strument i Seat the gauge mount firmly on the pinion head and swing the dial indicator through the differential bearing bore as shown in Fig N 29 j The lowest reading indicates the center of the differential bearing bore At this point the dial indi cator should read the same as mark etched on the pinion head If the...

Page 298: ...ween the pinion outer bearing and the pinion shaft to obtain correct torque reading N l7 Differential Case Reassembly Procedure for assembling the differential case on semifloating rear axles is as follows a Reassemble the differential pinions side gears thrust washers and shaft in relative position shown in Fig N 3 and N 7 Make sure the spacers are installed b Install differential shaft lock pin ...

Page 299: ... to Fig N 30 The adjustment of the differential bearings is main tained by the use of shims placed betwen the dif ferential case and the differential bearing Proce dure for adjusting bearing preload is as follows a Install the differential case and bearings in the axle housing without shims and with the bearing cups snug b Holding the ring gear in contact with the pinipn and using a screwdriver bl...

Page 300: ...im from one side to the other will change the amount of backlash approximately 003 0 076 mm m Check ring gear for runout A reading in excess of 006 0 152 mm indicates a sprung differential case dirt between the case and the gear or loose ring gear screws n In order to assist in determining whether the gears are properly adjusted paint the bevel gear teeth with red lead or prussion blue and turn th...

Page 301: ...erential case must also be changed on a stand ard differential assembly and the differential as sembly less ring gear and pinion when a Powr Lok differential assembly is involved When changing from any ratio to another it will also be necessary to change speedometer gears Speedometer gears for Powr Lok and standard differentials of the same ratio are interchangeable A complete rear axle assembly r...

Page 302: ...sive wear and pitting k Inspect the pinion gear races that bear on the side gear rings I Inspect the corresponding surfaces on the side gear rings m Inspect the clutch plates and discs for cracks and distortion In the event one or more of the clutch plates or discs needs replacing replace the entire stack of plates and discs on each side of the pinions These stacks are supplied in sets The differe...

Page 303: ...differential is serviced at the same time intervals as the standard differential N 26 Trouble Symptoms If noises or roughness such as chatter are present in turning corners the probable cause is incorrect or contaminated lubricant Before any differential is removed and disassem bled for chatter complaints the correctness of lubri cant can and should be determined A complete lubricant drain and ref...

Page 304: ...to allow clearance for the removal of the cross pin Place a few shop towels over the top of the vise to protect F I G N 4 2 R E M O V I N G R I N G G E A R the gear teeth from becoming nicked after it is free from the case Tap ring gear with a rawhide hammer to free it from the case Note It is recommended that whenever the ring gear screws are removed they are to be replaced with new screws d Remo...

Page 305: ...pin Use a hammer and punch as shown to remove the cross pin from the case Note A gear rotating tool C 4142 is required to service the Trac Lok diferential The Tool consists of four parts a Handle Pawl Forcing Screw and Step Plate j Assemble the step plate tool into the bottom side gear as shown in Fig N 46 k Position the gear rotating tool into the top side gear as shown in Big N 47 S 14342 F I G ...

Page 306: ...lutch pack in the case by holding hand on the bottom of the rotating tool while removing forcing screw Remove rotating tool top side gear and clutch pack F I G N 51 TRAC LOK U N I T D I S A S S E M B L Y s Remove the differential case from the axle shaft Turn case with the flange or ring gear side up and allow the step plate tool side gear and clutch pack to be removed from the case Remove the ret...

Page 307: ...s assembled to the side gear splines and that the retainer clips are completely seated into the pockets of the case To prevent pack from falling out of the case it will be necessary to hold them in place by hand while assembling the case onto the axle shaft F I G N 5 5 I N S T A L L D I F F E R E N T I A L C A S E ON A X L E S H A F T e Assemble differential case onto the axle shaft in the positio...

Page 308: ...ate gears exactly as shown Be sure the holes of the gears are lined up with each other Hold gears in place by hand See Fig N 59 k Tighten forcing screw so that the Belleville springs will compress and allow clearance between the teeth of the pinion mate gears and side gears F I G N 6 0 R O T A T I N G P I N I O N M A T E G E A R S I N T O P O S I T I O N I While holding the pinion mate gears in pl...

Page 309: ...s required the following steps should be followed b Remove both differential bearing cones and shims Mark or tag each side bearing cone and shim pack as it is removed to indicate from which side of the case they were removed c To remove ring gear from case follow the same steps as illustrated in Fig N 42 d Assemble ring gear to new Trac Lok case Fol low the same steps as illustrated in Fig N 63 Ma...

Page 310: ...ring the check d If all causes of backlash mentioned above have been eliminated with the exception of the differen tial and that still exceeds the maximum allowable movement overhaul the differential N 36 Rear Wheel Noise Looseness of the rear axle shaft nut on semifloat ing tapered rear axles may produce a clicking or creaking noise This noise can usually be stopped by torquing the wheel hub nut ...

Page 311: ... s G e a r R a t i o V 6 E n g i n e S t a n d a r d Optional F 4 E n g i n e Standard Optional R i n g G e a r P i t c h Diameter P i n i o n Adjustment P i n i o n B e a r i n g A d j u s t m e n t D a n a 27 Semifloating H y p o i d Gears 1 38 35 m m 2 3 73 1 4 88 1 4 56 1 7 75 19 68 cm S h i m S h i m D a n a 44 Semifloating H y p o i d Gears 1 50 38 0 mm 2 3 73 1 4 88 1 4 27 1 5 38 1 8 50 21 ...

Page 312: ......

Page 313: ...0 23 Steering Gear Adjustment 0 5 S T E E R I N G COLUMN AND W H E E L S E R V I C E 0 20 Steering Column Adjustments 0 4 Steering Wheel Installation 0 27 Steering Wheel Removal 0 21 S E R V I C E DIAGNOSIS 0 28 SPECIFICATIONS 0 29 i 1 B CJ 3B 0 0 0 1 Frame Cross Tube CJ 3B 2 Steering Beilcrank Bracket CJ 3B 3 Steering Beilcrank 4 Front Axle Assembly 5 Steering Connecting Rod Drag Link 6 Steering ...

Page 314: ...e steering arm moves forward the wheels turn to the right Ball joints are used to secure the drag link steering connecting rod and tie rod ends The ball joints assist in maintaining good steering control and con stant toe in of the front wheels under all driving conditions If the ball joints become worn enough to allow free motion in the linkage they should be replaced Note Ball joint replacement ...

Page 315: ...heel A l i g n m e n t A d j u s t m e n t s To ensure correct alignment a definite procedure for inspection of the steering system is recom mended It is suggested that the following sequence be used a Equalize tire pressures and level vehicle b Check steering gear to steering column align ment c Inspect steering knuckle pivots spindle and wheel bearing looseness d Check wheel runout e Test wheel ...

Page 316: ...imately one half turn 0 9 Front Wheel Camber The purpose of camber Fig 0 4 is to more nearly place the weight of the vehicle over the tire con tact on the road to facilitate ease of steering The result of excessive camber is irregular wear of tires on outside shoulders and is usually caused by bent axle parts The result of negative or reverse camber if ex cessive will be hard steering and possibly...

Page 317: ...on the screw to prevent any movement Refer to Fig O 6 The left steering knuckle arm controls the relation ship of the front wheels on a left turn and the right arm controls the relation on a right turn 0 12 Steering Knuckle Arm Should a steering knuckle arm become bent the knuckle housing must be replaced It is not safe to straighten the knuckle arm 0 13 Front Wheel S h i m m y Wheel shimmy may be...

Page 318: ...is of the ball and socket type All ball seat springs and adjusting plugs are 6 Dust Cover 7 Dust Shield 8 Small Adjusting Plug 9 Lubrication Fitting 10 Connecting Rod identical the only difference between front and rear end being the relative location of the springs The correct assembly of the steering connecting rod is shown in Fig 0 7 At the front or axle end the spring and spacer are assembled ...

Page 319: ...m 0 18 S t e e r i n g B e l l c r a n k Service Refer to Fig 0 9 The assembly and adjustment of this unit is ex tremely important the information outlined below must be followed carefully whenever servicing the bellcrank assembly on late model vehicles A service kit Part No 991381 containing the bell crank shaft bearings seals bolt nuts and washer is available for servicing this assembly Be certa...

Page 320: ...W H E E L S E R V I C E Jeep Universal Series vehicles use a one piece steer ing shaft that is integral with the steering gear assembly as shown in Fig 0 2 Alignment in structions in paragraph 0 4 apply 0 2 1 Steering W h e e l Removal Refer to Fig 0 2 a Carefully pry the rubber horn cap from the housing slot b Remove steering shaft nut c Remove steering wheel and spring 0 2 2 S T E E R I N G G E ...

Page 321: ...earing ball cup in the housing N o t e New plastic retainer type cam bearings are now available for the Ross steering gears The new bearings replace and are interchangeable with the lock ring type cam bearings on gears equipped with early type cams With adjusting shims in place assemble upper cover and adjust the cam bearings Assemble lever shaft in housing and with gasket in place assemble the si...

Page 322: ...r 0 29 S T E E R I N G S P E C I F I C A T I O N S F4 E N G I N E V6 E N G I N E S T E E R I N G G E A R Make Ross Ross Type Cam and Lever Cam and Lever Ratio 17 9 to 1 19 to 1 Bearings Ball Cam Upper Ball Ball Cam Lower Ball Ball Lever Shaft Bushing Bushing Steering Column Upper Ball Ball Lever Shaft 0005 to 0025 0 0127 a 0 0635 mm Clearance to Bushing 0005 to 0025 0 0127 a 0 0635 mm j 0005 to 00...

Page 323: ...cles The double safety brake system Is equipped with dual stop light switches that op erate independently of each other thus eliminating possible stop light failure Service information for self adjusting brakes starts with Par P 14 All four wheel drive vehicles are equipped with a transmission brake that operates in the drive line and is mounted to the rear of the transfer case Two wheel drive veh...

Page 324: ... wheel cylinders to activate both front and rear brakes Upon release of the brakes fluid re turns from the rear wheel cylinders through the secondary residual check valve to the secondary portion of the master cylinder bore Fluid also returns from the front wheel cylinders through the primary residual check valve to the primary portion of the master cylinder bore P 3 Parking Brakes DJ 5 DJ 6 a The...

Page 325: ...system must be checked and the self adjusting star wheel mechanisms checked for binding also the brake linings should be inspected as they may be badly worn How much lining is left can only be deter mined by visually inspecting the linings See Par P l6 for relining brakes d If the brakes pull to one side after adjustment check tire pressures All tires must be inflated to recommended pressures to e...

Page 326: ...inder and the wheel cylinders Note On some vehicles a proportioning valve is located in the rear brake line along the inside left frame side rail The valve is not serviceable and must be replaced as an assembly Should replacement be necessary make certain the valve is properly positioned with the centerline of the hex plug in the bottom of the valve in the vertical position Refer to Fig P l The ho...

Page 327: ... necessary free up the cable and lubri cate it Rotate the brake drum until one pair of the three sets of holes are over the shoe adjusting screw wheels in the brake Use the edge of the holes in the brake drum as a fulcrum for suitable adjusting tool or a screwdriver rotate each notched adjusting screw by moving the handle of the tool away from the center of the drive shaft until the shoes are snug...

Page 328: ...ontinuous adjustment prevents gradual increase in the brake pedal travel as the linings wear The adjuster therefore adds the safety feature of main taining adequate pedal reserve during the service life of the lining After the lining wears enough to require adjust ment the adjusting cable or link will lift the lever into engagement with the next tooth of the star wheel when the brake is applied Wh...

Page 329: ... ditioned in this manner either the correct factory supplied oversize lining 030 0 762 mm must be installed or a shim equal in thickness to the metal removed must be placed between the lining and shoe so that the arc of the lining will be the same as that of the drum If it is found when wheels are removed that there is brake fluid leakage at any of the wheel cylinders it will be necessary to repla...

Page 330: ... fi Assemble the short wire link with large hook by first inserting the S shape offset end into the lever crank hole which is closest to the hexagon head and then snap the hook end of the link in the top groove of the anchor pin i Insert the long link with S shaped end in the crank lever Lift the adjuster lever up enough to hook the link in the slot of the adjusting lever The adjusting lever will ...

Page 331: ...st ing tool or screw driver to rotate the star wheel until the wheel is in the locked position To tighten rotate the star wheel in the clockwise direction Then back off the star wheel at least 15 to 20 notches clicks d To back off the star wheel on the brake insert ice pick or thin blade screw driver in adjusting screw slot to hold lever away from adjusting screw Back off on adjusting screw until ...

Page 332: ...m each other Install the cup expander in the lip groove of the end cup cL Coat the cylinder bore and piston assemblies with clean brake fluid before installing any parts in the cylinder e Install the secondary piston assembly first and then the primary piston which is supplied in the repair kit f Install the push rod assembly which includes the push rod boot and rod retainer and secure with the sn...

Page 333: ...re for roughness or scoring Check fit of pistons to cylinder bore e When reassembling the cylinder dip springs pistons and piston cups in brake fluid Install spring in center of the wheel cylinder Install piston cups with the cupped surface towards the spring so that the flat surface will be against the piston Install pistons and dust covers f Install wheel cylinder to the backing plate and connec...

Page 334: ...Grease or Brake Fluid in Lining Shoes Improperly Adjusted Warped Brake Shoes Distorted Brake Drums Glazed or Worn Lining Restricted Brake Line Faulty Brake Cylinder Insufficient Brake Fluid S q u e a k y Brakes Shoes Warped or Drums Distorted Lining Loose Dirt Imbedded in Lining Improper Adjustment Oil or Grease on Lining Glazed or Worn Lining Drum Scored DIAGNOSIS P R O B A B L E R E M E D Y Adju...

Page 335: ...arried on two opposed tapered roller bearings as shown in Fig Q l and Q 2 Rear wheels are carried on a single tapered roller bearing mounted on each axle shaft as shown in Fig Q 3 Q 4 and Q 5 These bearings are adjustable for wear and their satis factory operation depends upon periodic attention and correct lubrication Q 2 Wheel Balancing Wheel balancing with the wheel on the vehicle is 18 17 1073...

Page 336: ... R W H E E L A T T A C H I N G P A R T S 2 W H E E L D R I V E T A P E R E D A X L E 1 Oil Seal 2 Bearing Cone 3 Bearing Cup 4 Shim Set 5 Retainer and Seal 6 Brake 7 Nut 8 Hub and Drum 9 Axle Shaft Key 10 Washer 11 Nut 12 Cotter Pin 13 Lockwasher 14 Bolt recommended with the exception that rear wheels on vehicles having Trac Lok or Powr Lok axles should always be removed for balancing Q 3 WHEEL BE...

Page 337: ...the nut lock washer so that the locknut and lock washer may be removed d Rotate the wheel and tighten the adjustment nut until the wheel binds Note Front tire and wheel must be rotated by hand as the adjusting nut is tightened to ensure positive seating of the bearing Then back off the adjusting nut about one sixth turn making sure that wheel rotates freely without sidewise shake e Replace the loc...

Page 338: ...B E A R I N G T A P E R E D A X L E S H A F T 1 Adjusting Shims 2 Inner Seal 3 Outer Seal keyway Never install the key in the keyway before placing the hub and drum assembly on the axle shaft Be sure that the axle shaft nut is torqued to a minimum of 150 lb ft 20 7 kg m O 10 BRAKE DRUM SERVICE On rear wheels the hub fits inside the brake drum Fig Q 3 On front wheels the hub is attached to the outs...

Page 339: ...els should be straight ahead or toe in slightly When there is excessive toe in or toe out tires will revolve with a side motion and scrape the tread rubber off Front tires will show wear on the outside with too great a toe in condition and on the inside with a toe out condition d BALANCE Cupping and bald spotting of tires is associated with wear on a vehicle driven mostly at high way speeds withou...

Page 340: ...wide treads The single letter in front of the 70 indicates load rating or the weight a tire can support safely when inflated to 32 psi The number 70 is used to show the 7 to 10 70 percent ratio of tire section height to width The last two digit number of the new sizes 15 is the rim diameter Radial ply tire sizes all contain the letter R to designate radial ply construction 15 inch Diameter New Old...

Page 341: ... e Vehicles that have been in an accident of any hide and carefully tack them m place Drop a nature which may result in a swayed or sprung gumb bob from each point indicated in Figures frame should always be carefully checked for a n L m a J k l g t h e u f l o r Meetly underneath proper frame alignment steering geometry and the point Satisfactory checking depends entirely axle alignment o n t h e...

Page 342: ... points of measurements may be considered as satis factory alignment These diagonals should also in tersect at the center line If the measurements do not agree within the above limits it means that correction will have to be made between those points that are not equal Note During the process of straightening the frame be extremely careful not to overstretch the J i L R TET 12875 F I G R 3 F R A M...

Page 343: ...ized where a frame section is squashed and must be brought out without tearing or excessive stretch to the metal R 5 Front Axle Alignment After it has been determined that the frame is prop erly aligned the front axle alignment with the frame can be checked The front axle is square with the frame if the distance between the front and rear axle is the same on both sides The dis tance from the sprin...

Page 344: ......

Page 345: ...xamined periodically for broken or shifted leaves loose or missing rebound clips angle of spring shackles and position of springs on the saddles Springs with shifted leaves do not have their normal strength Missing rebound clips may permit the spring leaves to fan out or break on rebound Broken leaves may make the vehicle hard to handle or permit the axle to shift out of line Weakened springs may ...

Page 346: ...he pivot bolt Disconnect the shackle either by re moving the lower nuts and bolts on rubber bushed shackles or by removing the threaded bushings on U shackles see Par S 6 S 5 Install Spring To install a spring first install the pivot bolt Then connect the shackle using the following procedure a On bronze bushed pivot bolts install the bolt and nut and tighten the nut Then back it off two cotter pi...

Page 347: ...he lower shank of the shackle They are used at the left front spring and the right rear spring with the left hand thread ed end DOWN at the spring eye The left hand threaded parts have been cancelled in the produc tion of Models CJ 3B CJ 5 and CJ 6 All later production vehicles up to early 1957 use all right hand threaded parts When replacing shackles and bushings on these vehicles examine the par...

Page 348: ...ubber bushings and shock absorber eyes are held in place on the mounting pins either by a flat washer and a cotter pin on Model CJ 3B or by a flat washer and a locknut on Models CJ 5 CJ 5A CJ 6 CJ 6A DJ 5 and DJ 6 To remove a shock absorber first remove the cotter pins or locknuts and washers Then pull the shock absorber eyes and rubber bushings from the mount ing pins To install a shock absorber ...

Page 349: ...O N T S P R I N G S Number of Leaves W i d t h Spring Rate R E A R S P R I N G S Width Spring Rate 6 395 100 65 cm 1 4 45 cm 260 lbs per in 5 46H 117 16 cm W K 45 cm 230 lbs r er in 10 39 100 65 cm IW 4 45 cm 176 lbs per in 5 46 H 117 16 cm IW 4 45 cm 230 lbs per in 5 395 100 65 cm 1 4 45 cm 188 lbs per in 5 463 117 16 cm 1 4 45 cm 230 lbs t er in S 9 SHOCK ABSORBER SPECIFICATIONS T Y P E Hydrauli...

Page 350: ......

Page 351: ...ions and welded All com ponent panels are seamed and welded together The body is insulated from the frame with insulator shims placed between the body and frame and held in position by the body bolts The instruments and controls mounted on the instrument panel are within clear view and easy to reach Note A new floor pan cover plate has been released on late CJ 5 and CJ 6 models that is identified ...

Page 352: ...with soft or canvas tops A hinged ven tilator mounted in the center of the panel directly under the glass is provided for ventilation The glass is installed in the same manner as on Models CJ 5 and CJ 6 Vehicles equipped with metal enclosure employ a stationary windshield which is the same as that used with the canvas top except that it has a higher silhouette and is wider Glass installation is th...

Page 353: ... Jeep U N I V E R S A L S E R I E S S E R V I C E MANUAL T 353 ...

Page 354: ...o remove the glass it is necessary to first remove the locking strip which may be pried out with a screwdriver or similar tool Installation is obvious T 5 Canvas Tops Canvas tops are available in Half Tops and Full Tops Installation instructions are provided with each canvas top kit for each model vehicle F I G T 5 V E H I C L E C O N T R O L S M O D E L CJ 5A CJ 6A S I N G L E L E V E R T R A N S...

Page 355: ...ontrols 17 Accelerator Pedal 18 Brake Pedal 19 Clutch Pedal 20 Hand Brake Control 21 Headlight Dimmer Switch On applicable models only solid in construction without groove Either grooved and solid pad covers can be installed on CJ 3B CJ 5 CJ 5A CJ 6 CJ 6A DJ 5 and DJ 6 models T 8 F r o n t S e a t A d j u s t m e n t The Bostrom bucket type driver s seat installed on early Models CJ 5 CJ 6 DJ 5 an...

Page 356: ... B R A K E P E D A L P A D F I G T 1 0 V E H I C L E C O N T R O L S M O D E L S DJ 5 A N D DJ 6 1 Light Switch 2 Windshield Wiper Switch 3 Hazard Warning Light Switch 4 Hand Throttle 5 choke Control 6 Windshield Washer Control 7 Ignition Starter Switch 8 Cigarette Lighter 9 Turn Signal Lever 10 Instrument Cluster 11 Horn Button 12 Glove Compartment 13 Heater Controls 14 Transmission Shift Lever 1...

Page 357: ...5 mph 21 6 to 24 0 kph at an engine speed of from 900 to 1000 rpm S U B J E C T P A R Heater U 10 Miscellaneous Data U 16 Pintle Hook 1X7 Special Tools U l l Torque Specifications U 13 14 15 Standard and Recommended Tools j U 12 U 5 Novi Governor Operation The Novi governor is directly belted to the F4 engine as no clutch is provided to disconnect the drive To operate the vehicle WITHOUT governor ...

Page 358: ...r W e i g h t The best performance of a four wheel drive vehicle is obtained when the load is equally distributed for traction on the front and rear wheels This weight distribution is disturbed when the vehicle is used for drawbar work as the load on the rear wheels is increased and that on the front wheels decreased The addition of a 265 pound front bumper weight equalizes the load When the load ...

Page 359: ...panel on the instrument panel A three position switch mounted in the control panel operates the heater fan F I G U 3 F R O N T B U M P E R W E I G H T F I G U 4 F R E S H A I R H E A T E R A N D D E F R O S T E R C J 5 A N D CJ 6 _ 1 Heater Assembly 2 Hose Clamp 3 Defroster Nozzle 4 Air Duct Screen 5 Air Duct and Heater Collar 6 Air Duct Intake Tube 7 Hose Clamp 8 Straight Hot Water Hose 9 Heater ...

Page 360: ...iver Alternator Rotor Bearing Small C 3936 Puller Alternator Rotor Bearing Small C 4068 Puller Alternator Rotor Bearing Large T r a n s m i s s i o n G r o u p KF 128 A Driver Main Drive Shaft Bearing W 166 Arbor Sleeve Countershaft Needle Bearing Aligning W 193 Arbor Countershaft Needle Bearing Aligning W 194 Plate Transmission Main Shaft Retaining W 329 Puller Main Drive Gear and Mainshaft Beari...

Page 361: ...g Differential Pinion Bearings Use with DD 914 P C 3 716 Driver Differential Carrier Bearing C 4142 Gear Rotating Tool Trac Lok Differential Jeep exclusive tool S t e e r i n g G r o u p C 3646 Puller Steering Shaft Arm B r a k e G r o u p W 172 Puller Parking Brake Drum U 12 STflNDfiRD AND RECOMMENDED TOOLS Tool Description ENGINE W 292 Tester Cooling System Thermostat C 119 Indicator Cylinder Bo...

Page 362: ...20 26 2 8 a 3 6 Clutch Control Ball Stud 7 93 mm 35 45 4 8 a 6 2 Connecting Rod Cap Bolt Nut y8 9 53 mm 35 45 4 8 a 6 2 60 70 8 3 a 9 7 Cylinder Head to Block Bolts 60 70 8 3 a 9 7 45 55 6 2 a 7 6 29 35 4 0 a 4 8 Flywheel to Crankshaft Bolt 35 41 4 8 a 5 7 Fuel Pump Mounting Bolts 13 17 1 8 a 2 4 Alternator Bracket to Cylinder Block 25 35 3 5 a 4 8 29 35 4 0 a 4 8 Main Bearing Caps 65 75 9 0 a 10 ...

Page 363: ...Flywheel to Crankshaft Oil Pan to Cylinder Block Oil Pan Drain Plug Oil Pump Cover to Timing Chain Cover Oil Pump Pressure Valve Cap Oil Screen Housing to Cylinder Block Oil Pan Baffle to Cylinder Block Oil Gallery Plugs Filter Assembly to Pump Cover Timing Chain Cover to Block Water Pump Cover to Timing Chain Cover Fan Driven Pulley Thermostat Housing to Intake Manifold Intake Manifold to Cylinde...

Page 364: ... Retainer Bolts S 10 15 1 4 a 2 1 Steering Knuckle Support to Knuckle Arm to Wheel Spindle Bolt 45 55 6 2 a 7 6 Steering Mounting to Frame Y 9 53 mm 30 40 4 1 a 5 5 Steering Mounting to Frame W 11 11 mm i 45 55 6 2 a 7 6 Steering Tie Rod Clamp Bolts 7 94 mm 10 15 1 4 a 2 1 Steering Tie Rod Clamp Bolts Ke U H mm 35 45 4 8 a 6 2 Steering Wheel Nut 32 38 1 2 7 a 5 2 Transmission Mainshaft Nut 130 170...

Page 365: ...e a draw bar pull as high as 1800 pounds 817 kg may be safely used Maximum continuous draw bar pulls are most often encountered in plowing disking and har rowing and it is in these applications that the owner should guard against continuously exceeding the recommended limit The approved limit of 1200 pounds 544 kg may be judged by the following operations which nearly approach this limit Operating...

Page 366: ... 929 5 78 14 05 1875 1675 10 43 25 36 2600 2600 16 19 39 33 2600 POWER TAKE OFF SHAFT AND VEHICLE GROUND SPEEDS ALL GEAR SHIFT POSITIONS KILOMETERS PER HOUR Governor Control Position Transfer In POWER T A K E O F F 1 T O 1 G E A R RATIO Engine Speed Governor Control Position Transfer In Transmission Gear In Engine Speed Governor Control Position Transfer In Li W Internlediate H gh Engine Speed Gov...

Page 367: ... zero pounds through 1200 pounds 544 kg maximum recommended in steps of 300 pounds 136 kg Governed Engine R P M Vehicle Speed M P H Draw Bar H P H P A T P T O S P L I N E SHAFT Governed Engine R P M Vehicle Speed M P H Draw Bar H P Vehicle Stationary 3600 Lb Vehicle Mov ng with Governed Engine R P M Vehicle Speed M P H Draw Bar H P Vehicle Stationary No Lbs Draw Bar Pull 300 Lbs Draw Bar Pull 800 ...

Page 368: ...l 405 Kg Draw Bar Pull 540 Kg Draw Bar Pull 1000 S 7 28 1 6 J 13 9 12 1 10 3 8 5 6 7 1200 4 4 8 74 20 6 17 4 15 2 13 2 10 9 8 7 1400 S 0 10 20 248 21 1 18 6 16 1 13 5 10 9 1800 5 8 11 65 28 9 24 6 21 8 19 1 18 8 13 1 1800 6 4 13 11 33 5 27 2 25 7 22 5 19 3 16 0 2000 7 2 14 58 33 5 33 5 30 4 26 8 23 2 19 6 1200 8 9 16 02 3 3 J 33 5 33 0 28 9 25 0 21 0 2400 8 7 17 48 33 5 33 5 33 5 30 2 25 8 21 5 26...

Page 369: ...s per hour square centimeter No number s outside diameter cm3 cubic centimeter O D number s outside diameter cp candle power O S cp O S over size cu in cubic inches oz ounces cw clockwise cw clockwise P T O Power Take Off C C W counter clockwise paragraph C C W counter clockwise Par paragraph dia diameter psi pounds per square inch F fahrenheit r h right hand Fig figure s rpm revolutions per minut...

Page 370: ......

Page 371: ...D 35 Dl 36 Cylinder Head D 17 D 73 D 98 Dl 24 Dl 63 Dl 82 Cylinder Head Torque C 5 Dash Pot Adjustment C 26 E 44 Differential B 51 thru B 53 N 9 Differential Adjustments N 16 N 18 Differential Powr Lok N 20 Differential Trac Lok N 24 Directional Signal Lights H 138 Distributor B 14 B 15 C 10 D 13 Dl 9 H 9 H 20 Distributor Check H l7 H 28 Distributor Point Dwell C 17 Distributor Resistance Test C 1...

Page 372: ...Pivot Bolts S 3 Spring Shackles S 2 Spring Specifications S 8 372 Starting Motor B 18 H 92 H 108 Starting Motor Bearings B 75 Starting Motor Bendix Drive H 105 H 106 Starting System H 7 H 88 Starting System Maintenance H 93 Stator Alternator H 84 Steering O l Steering Arm P 10 Steering Column Adjustments 0 4 Steering Column and Wheel Service O 20 Steering Gear B 27 0 22 Steering Gear Adjustment 0 ...

Page 373: ...NOTES ...

Page 374: ...N O T E S ...

Page 375: ...NOTES ...

Page 376: ...NOTES ...

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